Thermal Systems Design Engineer

Job Title: Thermal Systems Design Engineer

Job Summary:

We are seeking an experienced Senior Thermal Systems Design Engineer to lead the end-to-end development of advanced thermal management solutions for applications in energy systems, aerospace, electric vehicles, electronics cooling, data centers, or process industries. The ideal candidate will have deep expertise in thermal-fluid sciences, simulation, design integration, and cross-functional leadership. You will play a key role in shaping thermal architecture, ensuring system reliability, and mentoring junior engineers.

Key Responsibilities:

System Architecture & Technical Leadership:

• Define and lead the thermal architecture and performance strategy for complex mechanical systems involving cooling, heating, insulation, and phase-change processes.

• Lead root cause analysis and resolution of thermal challenges in prototype and production stages.

• Ensure thermal solutions are optimized for cost, weight, manufacturability, and operational efficiency.

Advanced Modeling & Simulation:

• Oversee the development and validation of 1D and 3D thermal models using ANSYS Fluent, COMSOL, GT-SUITE, or equivalent tools.

• Drive parametric studies, sensitivity analysis, and system-level trade-off evaluations.

Cross-Functional Engineering & Integration:

• Collaborate with mechanical, electrical, controls, and product design teams to integrate thermal subsystems into full product platforms.

• Participate in system requirements definition and flow-down related to thermal, reliability, and compliance.

Testing, Validation & Compliance:

• Define thermal validation plans, oversee test setups, and analyze test data to validate models and performance.

• Ensure compliance with standards such as ASME, API, ISO, SAE, or MIL-SPEC depending on industry application.

Mentorship & Innovation:

• Mentor junior and mid-level engineers in best practices for thermal system design, modeling, and validation.

• Drive R&D initiatives in emerging thermal technologies (e.g., advanced materials, passive cooling, AI-assisted optimization).

Key Focus Areas:

• Lead thermal system design and architecture

• Guide simulation, validation, and integration

• Innovate and optimize thermal solutions

• Mentor engineering staff and drive cross-functional design reviews

Qualifications and Skills:

Education:

• Bachelor’s Degree in Mechanical, Aerospace, Thermal Engineering, or related field (Master’s or PhD preferred)

Certifications:

• Professional Engineering (PE) license or equivalent preferred

• Certified in thermal simulation or modeling tools (e.g., ANSYS, COMSOL, GT-SUITE)

Experience:

• 8–12+ years of experience in thermal system design, modeling, and analysis

• Demonstrated success in leading the design of thermal subsystems for industrial or high-performance applications (e.g., EV batteries, avionics, gas turbines, electronics, or data centers)

Technical Skills:

• Deep knowledge of thermodynamics, conduction, convection, radiation, and multiphase systems

• Proficient with CAD and thermal/fluid analysis tools

• Familiarity with instrumentation for thermal validation (thermocouples, IR imaging, flow meters)

Soft Skills:

• Strong leadership, project management, and stakeholder communication skills

• Ability to deliver under tight schedules with high accuracy

• Continuous improvement mindset and attention to innovation