Power Electronics - Thermal Engineer Senior Staff

Shieldai; Dallas (TX); On-site; USD 120,000 - 150,000; Full time

Benefits offered by this job

Salary with bonus and equity

Comprehensive benefits package

Job summary

Shieldai, located in Dallas, Texas, is searching for a Senior Staff Thermal Engineer to lead the design and integration of thermal management systems for aircraft. The ideal candidate should have a strong background in avionics thermal engineering and robust problem-solving abilities.

With a minimum of 7 years of experience and expertise in heat transfer and fluid mechanics, you will drive technical leadership across design teams. Opportunities for mentorship and innovation await you in this fast-paced environment.

Qualifications

• Minimum 7 years of professional experience in avionics or electronics thermal engineering.
• Ability to obtain an S/SAR level security clearance is desired.
• Proven ability to learn and adapt quickly in a fast-paced environment.

Responsibilities

• Own thermal analysis for UAV avionics including power electronics.
• Develop models for heat transfer using CFD tools.
• Drive test planning and data analysis for experimental results.

Skills

Heat transfer expertise

Fluent in fluid mechanics

Proficient in ANSYS Icepak

Strong communication skills

Education

B.S. in Mechanical Engineering or Aerospace Engineering

Tools

CFD tools (FloEFD, STAR-CCM+)

CAD design tools (NX, SolidWorks)

Job description

Founded in 2015, Shield AI is a venture‑backed defense‑tech company with the mission of protecting service members and civilians with intelligent systems. Its products include Hivemind autonomy software and V‑BAT and X‑BAT aircraft. With offices and facilities across the U.S., Europe, the Middle East, and Asia‑Pacific, Shield AI’s technology actively supports operations worldwide. Company website: www.shield.ai.

Job Description

Are you a passionate and innovative thermal engineer looking to help develop state‑of‑the‑art aircraft? Are you eager to make a positive difference in the world? Do you want to work alongside mission‑driven and values‑focused teammates? Shield AI is just the place for you! As a Senior Staff Thermal Engineer at Shield AI, you will lead the design, analysis, and integration of aircraft avionics thermal management systems. We are designing a high voltage, high power system using custom power electronics and energy storage. This role is best suited for an engineer who thrives on first‑principles problem solving, is comfortable with ambiguous, open‑ended challenges, and can bridge technical disciplines with strong communication and collaboration skills and the ability to simplify and communicate complex problems. The engineer will be a key contributor in shaping designs, mentoring peers, and ensuring robust thermal solutions that meet mission‑critical aerospace requirements.

Responsibilities

• Own thermal analysis and design efforts for unmanned aerial vehicle avionics including custom power electronics
• Develop and validate analytical, numerical, and computational models for heat transfer and fluid flow using hand calculations and CFD tools such as FloEFD
• Provide technical leadership in trade studies, system architecture decisions, and risk assessments
• Lead cross‑functional teams designing power electronic circuits and environmental enclosures. Provide design requirements that impact circuit part selection, board layout, material selection, and other design aspects
• Drive test planning, instrumentation, and data analysis to correlate models with experimental results
• Mentor junior engineers and guide cross‑disciplinary teams in applying thermal/fluid fundamentals
• 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 7 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 an S/SAR level security clearance desired

Benefits

Full‑time regular employee offer package: 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 but not limited to skill set, level of experience, licenses and certifications, and specific work location. All offers are contingent on a cleared background and possible reference check. Military fellows and part‑time employees are not eligible for benefits.

Equal Opportunity Employment

Shield AI is proud to be an equal opportunity workplace and is an affirmative action employer. We are committed to equal employment opportunity regardless of race, color, ancestry, religion, sex, national origin, sexual orientation, age, marital status, disability, gender identity or Veteran status. If you have a disability or special need that requires accommodation, please let us know.