Sr Staff Engineer, HVAC + Thermal Systems

Aptera Motors; Carlsbad (CA); On-site; USD 180,000 - 280,000; Full time

Job summary

Aptera Motors seeks a Senior Staff Engineer, HVAC & Thermal Systems, to lead thermal architecture and HVAC development for our solar EV platform. You will own the thermal strategy to maximize range, efficiency, and occupant comfort while safeguarding battery and electronics.

You will drive CFD/1D/3D modeling, validate through climate chamber work, and collaborate with battery, powertrain, and body teams to integrate systems across the vehicle.

Qualifications

• 15+ years of experience in automotive HVAC, thermal systems, or thermal management engineering.
• Deep expertise in vehicle HVAC systems and thermal architecture, including battery thermal management.

Responsibilities

• Lead HVAC design, development, and validation for a solar EV platform.
• Define thermal architecture strategy balancing energy efficiency, range, and comfort.
• Own system requirements, specs, and performance targets from concept to production.
• Lead CFD and 1D/3D modeling to predict and optimize performance.
• Plan HVAC validation programs including climate chamber testing and real-world verification.
• Collaborate with battery, powertrain, body, and electrical teams for integration.
• Manage suppliers for compressors, heat exchangers, refrigerants, and heat pumps.
• Provide technical leadership and mentorship to engineers.
• Drive root-cause analysis for thermal-related issues.
• Ensure designs comply with automotive thermal and refrigerant safety standards.
• Maintain BOM documentation.

Skills

Automotive HVAC

Thermal systems

CFD

Thermal validation

Cross-functional collaboration

Mentorship

Communication

Education

Bachelor's degree in Mechanical Engineering

Master's degree preferred

Tools

CATIA V6

Job description

About the role

Aptera is seeking a Senior Staff Engineer, HVAC & Thermal Systems to lead thermal architecture and HVAC system development for our solar electric vehicle. In this role, you’ll define and execute the thermal strategy that keeps our vehicle’s occupants comfortable and its battery, powertrain, and electronics running efficiently, all while protecting the ultra-low energy consumption that makes Aptera’s solar vehicle possible.

What you’ll do

• Lead the design, development, and vehicle validation of HVAC and thermal management systems for Aptera’s solar vehicle platform, including battery thermal management (all systems), cabin climate control, and power electronics cooling
• Define thermal architecture strategy that balances energy efficiency, range, and occupant comfort, a critical trade-off given the vehicle’s ultra-aerodynamic, solar-charging design
• Own thermal system requirements, specifications, and performance targets from concept through production
• Lead HVAC calculations and simulation work (CFD, 1D/3D modeling) to predict, validate, and optimize system performance ahead of physical testing
• Plan and lead HVAC system validation and thermal programs, including climate chamber testing, hot/cold weather development, and real-world performance verification
• Partner cross-functionally with battery, powertrain, body, and electrical teams to integrate thermal systems into the overall vehicle architecture
• Select and manage relationships with HVAC and thermal component suppliers, including compressors, heat exchangers, refrigerant systems, and heat pumps
• Provide technical leadership and mentorship to junior and mid-level HVAC and/or thermal engineers
• Drive root-cause analysis and resolution of thermal-related field and test issues
• Ensure HVAC system designs comply with relevant automotive thermal and refrigerant safety standards
• Maintain accurate HVAC and thermal systems documentation within the vehicle’s Build of Materials (BOM)

Qualifications

• 15+ years of relevant experience in automotive HVAC, thermal systems, or thermal management engineering
• Deep expertise in vehicle HVAC systems and thermal architecture, including battery thermal management systems for electric vehicles
• Proven track record leading thermal system design from concept through production launch
• Strong background in CFD and thermal simulation tools
• Hands-on experience with climate chamber and physical thermal validation testing
• Experience with HVAC systems and its major components and technologies
• Strong cross-functional collaboration skills, working closely with battery, powertrain, and body engineering teams
• Demonstrated technical leadership and mentorship of engineering teams
• Excellent communication skills, with the ability to translate complex thermal engineering concepts for cross-functional stakeholders

Preferred Qualifications

• Experience with solar-integrated or ultra-high-efficiency vehicle platforms
• Experience designing HVAC systems specifically optimized for range extension in EVs
• Proficient with CATIA V6 or similar automotive CAD/simulation tools
• Experience working in a startup or fast-paced product development environment
• Patents, publications, or conference contributions in automotive thermal management

Team Structure

• Individual contributor; collaborate with other teams and individuals, as necessary

Required Experience

• 15+ years of relevant experience in automotive HVAC, thermal systems, or thermal management engineering

Educational Requirements

• Bachelor’s degree in Mechanical Engineering, Thermal Engineering, or a related field; Master’s degree preferred

Salary + Benefits

• Market competitive compensation package
• Stock option grants
• Fully funded benefits package for employee + dependents
• Generous Flexible Time Away policy