Thermal Analysis Engineer, Battery

Archer; San Jose (CA); On-site; USD 144,000 - 180,000; Full time

Job summary

Archer is seeking an engineer in San Jose, CA to conduct thermal analysis and simulation of battery packs for our all-electric VTOL programs. You will develop efficient workflows, design thermal management solutions, and collaborate across mechanical, electrical, and control teams.

You will use CFD/CAE tools (STAR-CCM+ or Ansys Fluent), apply heat transfer and thermodynamics knowledge, and document findings in reports. Prior EVTOL or HV battery experience is a plus.

Qualifications

• Experience with CFD/CAE toolchains and battery thermal modelling.
• Strong foundation in heat transfer, fluid dynamics, and thermodynamics.
• Programming experience in Python or Matlab/Simulink.

Responsibilities

• Conduct thermal analysis and simulation of battery packs and modules.
• Develop efficient simulation methods and workflows.
• Design and optimize battery thermal management systems (e.g., cooling plates, HV battery TBMs).
• Plan and execute thermal testing to validate and improve models.
• Collaborate with mechanical, electrical, control, and systems engineering teams.
• Document results, design recommendations, and testing outcomes in reports and presentations.

Skills

CFD/CAE knowledge

Heat transfer

Fluid dynamics

Thermodynamics

Programming (Python/ Matlab/ Simulink)

Technical communication

Tools

STAR-CCM+

Ansys Fluent

Job description

Archer is an aerospace company based in San Jose, California building an all-electric vertical takeoff and landing aircraft with a mission to advance the benefits of sustainable air mobility. We are designing, manufacturing, and operating an all-electric aircraft that can carry four passengers while producing minimal noise.

Our sights are set high and our problems are hard, and we believe that diversity in the workplace is what makes us smarter, drives better insights, and will ultimately lift us all to success. We are dedicated to cultivating an equitable and inclusive environment that embraces our differences, and supports and celebrates all of our team members.

What you’ll do:

• Conduct thermal analysis and simulation of battery packs and modules using CAE tools.
• Develop efficient simulation methods and workflows.
• Design and optimize battery thermal management systems (e.g., cold plates, phase change materials) for performance and safety.
• Plan and execute thermal testing to validate and improve models.
• Collaborate with mechanical, electrical, control, and systems engineering teams to integrate thermal solutions and models.
• Document results, design recommendations, and testing outcomes in reports and presentations.

What you need:

• Familiarity with CFD/CAE tools (e.g., STAR-CCM+ or Ansys Fluent).
• Strong foundation in heat transfer, fluid dynamics, thermodynamics, and electrical fundamentals.
• Understanding of numerical methods and simulation workflows.
• Familiarity with programming (Python or Matlab/Simulink).
• Strong technical, written, and verbal communication skills.

Bonus skills:

• Experience with eVTOLs or other electric aircraft programs.
• Experience with Thermal Management System design for high-voltage (HV) Battery.
• Experience with software development best practices, including Git, CICD, and Conda.
• Experience with experimental data processing and reduction techniques.
• Knowledge of model verification, validation, calibration, and uncertainty quantification.

At Archer, we aim to attract, retain, and motivate talent with the skills and leadership needed to grow our business. We drive a pay-for-performance culture and reward performance that support the Company's strategy. For this position, we are targeting a base pay range of $144,000 - $180,000. Actual compensation offered will be determined by job-related knowledge, skills, and experience.

Archer is committed to working with and providing reasonable accommodations to job applicants with physical or mental disabilities, and those with sincerely held religious beliefs. Applicants who may require reasonable accommodation for any part of the application or hiring process should provide their name and contact information to Archer’s People Team at [e-mail]. Reasonable accommodations will be determined on a case-by-case basis.

Archer is unable to provide work visa sponsorship for this position at the present time.

Archer is proud to be an Equal Opportunity employer committed to diversity and inclusivity in the workplace. All aspects of employment are decided on the basis of merit, qualifications, and business needs. We do not discriminate based upon race, color, religion, sex, sexual orientation, age, national origin, disability status, protected veteran status, gender identity or any other characteristic protected by federal, state or local laws.