The Mid-Level Thermal Systems Engineer is responsible for the design, analysis, and integration of thermal control systems used in aerospace platforms, supporting critical functions such as cabin climate control, avionics cooling, and payload temperature regulation. The engineer performs detailed heat transfer calculations, system modeling, and test correlation to ensure thermal systems meet mission requirements for safety, performance, and reliability across all phases of development and operation.
Key Responsibilities:
Design, analyze, and optimize thermal systems and subsystems using heat exchangers, fans, liquid loops, or thermal insulation materials
Perform detailed thermal/fluid modeling and simulations (steady-state and transient) for aerospace environments including high-altitude and vacuum conditions
Support thermal integration of cabin HVAC, avionics enclosures, or mission payloads with broader vehicle systems
Develop and validate thermal models using tools such as Thermal Desktop, SINDA/FLUINT, ANSYS, or MATLAB/Simulink
Prepare technical documentation, including thermal design reports, interface control documents (ICDs), and compliance analyses
Support component selection, procurement, and vendor technical coordination for thermal hardware
Participate in lab, ground, or flight test campaigns; correlate test data with predictive models
Work with cross-functional teams (mechanical, electrical, ECS, structures, avionics) to ensure seamless integration
Contribute to risk assessments, failure investigations, and continuous improvement initiatives in thermal performance and reliability
Key Focus Areas:
Thermal system design for aerospace platforms (crew/cabin, electronics, or payloads)
Analytical modeling and simulation of heat transfer and fluid flow
Thermal test support and model correlation
Cross-discipline integration and technical documentation
Qualifications & Skills:
Education:
Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related discipline (required)
Master’s degree with a focus on heat transfer or thermal systems (preferred)
Experience:
3–6 years of hands-on experience in aerospace thermal systems engineering
Experience designing or analyzing ECS, avionics cooling, or payload thermal control systems
Involvement in hardware integration, lab testing, or flight testing is highly desirable
Technical Skills:
Proficient in thermal/fluid simulation tools (e.g., Thermal Desktop, SINDA/FLUINT, ANSYS Fluent, COMSOL, MATLAB/Simulink)
Working knowledge of CAD software (e.g., SolidWorks, Creo, NX) for design and integration reviews
Familiarity with environmental test standards and aerospace compliance requirements (e.g., DO-160, MIL-STD-810, RTCA)
Soft Skills:
Strong technical communication, including clear documentation and verbal presentations
Ability to work independently and collaboratively across technical teams
Analytical mindset with solid troubleshooting and systems-thinking skills
Organized, detail-oriented, and capable of managing multiple priorities