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

Shieldai; Seattle (WA); On-site; USD 140,000 - 210,000; Full time

Benefits offered by this job

Bonus

Benefits

Equity

Job summary

Shield AI is seeking a Sr. Staff Thermal Engineer to lead the design, analysis, and integration of aircraft avionics thermal management systems, with opportunities to expand to system-level cooling and flight electronics.

The role requires 7+ years in avionics/electronics thermal engineering, deep heat transfer and fluid mechanics knowledge, and strong CFD and CAD experience. MS/PhD and security clearance are preferred.

Qualifications

• B.S. in Mechanical or Aerospace Engineering; 7+ years in avionics thermal engineering.
• Deep knowledge of heat transfer and fluid mechanics.
• Experience with CFD tools: ANSYS Icepak, FloEFD, STAR-CCM+.
• CAD experience with NX or SolidWorks.
• Ability to mentor peers and present to stakeholders.

Responsibilities

• Lead design, analysis, and integration of avionics thermal systems.
• Develop models and validate against test data.
• Plan tests, instrumentation, and data analysis.
• Brief executives and reviews with clear written reports.
• Identify risks and influence design direction.

Skills

Heat transfer

Fluid mechanics

Active cooling

Passive cooling

CFD tools

ANSYS Icepak

FloEFD

STAR-CCM+

NX

SolidWorks

Technical leadership

First-principles reasoning

Communication skills

System integration

Security clearance desired

Education

B.S. Mechanical Engineering or Aerospace Engineering

M.S. or Ph.D. in relevant engineering

Tools

NX CAD

SolidWorks CAD

FloEFD CFD

STAR-CCM+

ANSYS Icepak

Job description

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, V-BAT and X-BATaircraft, and Aechelon simulation and synthetic reality technologies. 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 Sr. Staff Thermal Engineer at Shield AI, you will lead the design, analysis, and integration of aircraft avionics thermal management systems, with opportunities to flex into aircraft-level thermal and fluid systems.

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.

• 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.
• 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 a S//SAR level security clearance desired.
• M.S. or Ph.D. 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 (pumps, heat exchangers, composites, etc.)
• Experience guiding trade studies, proposals, and customer interactions in aerospace or defense programs.
• Background in multi-disciplinary system integration, spanning avionics, fluid systems, and systems engineering

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.