Senior Engineer, Avionics Thermal Engineering (R5298)

Shield AI; Dallas (TX); On-site; USD 110,000 - 170,000; Full time

Benefits offered by this job

Equity

Bonus

Benefits

Job summary

Shield AI is seeking a Senior Thermal Engineer to own the design, analysis, and integration of aircraft avionics thermal management systems and electronics cooling. You will lead first-principles, CFD-driven solutions for unmanned aircraft, coordinating across engineering teams to ensure robust thermal performance.

The role requires at least 4 years in avionics/thermals, strong heat transfer and fluid mechanics knowledge, and hands-on testing experience.

Qualifications

• BS in Mechanical or Aerospace engineering.
• 4+ years in avionics or electronics thermal engineering.
• Strong heat transfer and fluid mechanics knowledge.
• Active and passive cooling experience.
• Familiarity with TIMs and cooling components.
• Proficiency with CFD tools (ANSYS Icepak, FloEFD, STAR-CCM+).
• CAD tools such as NX or SolidWorks.
• Strong written and verbal communication.
• Ability to learn new tools in a startup environment.

Responsibilities

• Own thermal solutions for UAV avionics including design, analysis, and test.
• Develop and validate heat transfer and fluid flow models.
• Lead trade studies and risk assessments in thermal system design.
• Plan tests, instrument, and analyze data to validate models.
• Guide cross-disciplinary teams on thermal-fluid fundamentals.
• Present findings in design reviews and reports.
• Identify risks and influence design direction.

Skills

Thermal analysis

CFD

Heat transfer

Fluid mechanics

First-principles reasoning

Technical communication

Problem solving

Learning agility

Education

B.S. in Mechanical or Aerospace engineering

M.S. in engineering (preferred)

Tools

NX

SolidWorks

FloEFD

ANSYS Icepak

STAR-CCM+

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. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X, Instagram, and YouTube.

Job Description:

Are you a passionate and innovative thermal engineer looking to help develop state of the art AI and aircraft products? 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 Thermal Engineer at Shield AI, you will own the design, analysis, and integration of aircraft avionics thermal management systems and electronics cooling.

This role is best suited for an engineer who thrives on first-principles problem solving, is comfortable with ambiguous, open-ended challenges, and can communicate well across functions, ensuring well coordinated thermal management solutions.

What you’ll do:

• Own thermal solutions for unmanned aerial vehicle avionics including design, analysis, and test.
• 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.
• Drive test planning, instrumentation, and data analysis to correlate models with experimental results.
• Guide cross-disciplinary teams in applying thermal/fluid fundamentals.
• Communicate technical findings clearly through design reviews, and written reports.
• Proactively identify risks, propose solutions, and influence electrical and/or PCBA design direction.

Required qualifications:

• B.S. in Mechanical Engineering, Aerospace Engineering, or related discipline.
• Minimum 4 years of professional experience in avionics or electronics thermal engineering.
• Strong expertise in heat transfer (conduction, convection, radiation) and fluid mechanics.
• Strong understanding of active and passive cooling solutions and their integration at component and system level.
• 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+).
• Experience 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.
• Proven ability to learn and adapt quickly to new tools, processes, and technical challenges in a fast paced, startup environment.

Preferred qualifications:

• M.S. in a relevant engineering discipline.
• Experience with high altitude aircraft avionics cooling and thermal design.
• Familiarity with aircraft integration constraints (power, weight, volume, maintainability, safety).
• Hands-on experience with thermal and fluid system testing, instrumentation, and validation.
• Knowledge of materials and manufacturing methods relevant to thermal management

$110,000 - $170,000 a year

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. Please speak to your talent acquisition representative for more information.

Shield AI is proud to be an equal opportunity workplace and is an affirmative action employer. We are committed toequal 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.