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Sr. Staff Thermal Engineer - Aircraft Avionics & Thermal Systems (R3930)

Shield AI· X-BAT Division – X-BAT Engineering - Mechanical
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Seattle, WA, San Diego, CA$200k - $310kFull Time EmployeePosted 7mo ago

About the role

Senior-level thermal engineer leading design, analysis, and integration of aircraft avionics thermal management systems with opportunities to contribute to aircraft-level thermal and fluid systems, mentoring peers, and influencing design directions in a fast-paced defense-tech environment.

Responsibilities

  • Contribute to thermal analysis and design efforts for unmanned aerial vehicle avionics and thermal/fluid systems.
  • Develop and validate analytical, numerical, and computational models for heat transfer and fluid flow using hand calculations and CFD tools such as FloEFD.
  • Drive test planning, instrumentation, and data analysis to correlate models with experimental results.
  • Communicate technical findings clearly through executive-level briefings, design reviews, and written reports.
  • Proactively identify risks, propose solutions, and influence electrical and/or PCBA design direction.

Qualifications

  • B.S. in Mechanical Engineering, Aerospace Engineering, or related discipline.
  • Minimum 10 years of professional experience in avionics or electronics thermal engineering.
  • Strong expertise in heat transfer (conduction, convection, radiation) and fluid mechanics.
  • Deep understanding of active and passive cooling solutions and their integration at component and system level.
  • Deep understanding of thermal management design elements including TIMs, spreaders, heat sinks, vapor chambers, heat pipes, and fans
  • Proficiency with thermal analysis and CFD tools (e.g., ANSYS Icepak, FloEFD, STAR-CCM+).
  • Proficiency with CAD design tools such as NX, SolidWorks, or similar.
  • Demonstrated experience applying first-principles reasoning to complex engineering problems.
  • Strong written and verbal communication skills, with a track record of leading technical discussions and presenting to stakeholders.
  • Proven ability to learn and adapt quickly to new tools, processes, and technical challenges in a fast paced, startup environment.
  • Ability to obtain a S//SAR level security clearance desired.

Skills

Required:Thermal analysisCFD toolsHeat transferActive and passive coolingTIMs, spreaders, heat sinks, vapor chambers, heat pipes, fansCAD tools (NX, SolidWorks)

Benefits

  • Pay within range listed + Bonus + Benefits + Equity
  • Temporary employee offer package: Pay within range listed above + temporary benefits package (applicable after 60 days of employment)
  • Salary compensation is influenced by a wide array of factors including skill set, level of experience, licenses and certifications, and specific work location. All offers contingent on cleared background and possible reference check.
  • Military fellows and part-time employees are not eligible for benefits.
Last updated Oct 23, 2026. Interested? Apply on the company site.

About Shield AI

Autonomy for the world.

Our mission is to protect service members and civilians with intelligent systems.

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