The Senior Thermal Systems Engineer leads the design, analysis, integration, and validation of advanced thermal management solutions for aerospace applications—including cabin climate control, avionics thermal regulation, and mission-critical payload cooling. This role serves as a technical authority, guiding multidisciplinary teams through system architecture development, thermal modeling, hardware selection, and verification across the full product lifecycle. The engineer ensures performance, safety, and compliance with aerospace standards in complex and often constrained environments.
Key Responsibilities:
Lead the development and validation of active and passive thermal control systems for aerospace platforms (aircraft, spacecraft, or UAVs)
Develop and own thermal architectures and performance models across multiple systems: cabin ECS interfaces, avionics enclosures, and payloads
Perform high-fidelity simulations for conduction, convection, radiation, and fluid dynamics using advanced tools (e.g., Thermal Desktop, SINDA/FLUINT, ANSYS Fluent, COMSOL)
Direct thermal analysis activities through all phases: conceptual studies, detailed design, trade-offs, verification planning, and failure analysis
Lead thermal subsystem integration with structures, ECS, avionics, power systems, and environmental qualification teams
Plan and analyze ground and flight test campaigns, including correlation of test results with analytical models
Ensure compliance with aerospace standards and regulatory requirements (e.g., DO-160, ARP4754, FAR 25, MIL-STD-810)
Mentor junior and mid-level engineers in thermal design methodology, tools, and technical decision-making
Interface with internal stakeholders, suppliers, and customers to communicate design intent, performance metrics, and risk mitigation strategies
Key Focus Areas:
High-reliability thermal systems for manned/unmanned aerospace platforms
Advanced modeling and analysis of thermal and airflow systems
Integration of thermal management into multidisciplinary systems
Verification, testing, and regulatory compliance leadership
Qualifications & Skills:
Education:
Bachelor’s degree in Mechanical, Aerospace, or Thermal Engineering (required)
Master’s degree or Ph.D. with a focus in thermal sciences or fluid dynamics is highly desirable
Experience:
7–12+ years of experience in thermal systems engineering for aerospace vehicles
Proven record of leading design and integration of avionics cooling, cabin thermal systems, or payload thermal control systems
Hands-on experience with both analytical model development and test data validation
Involvement in full product lifecycle from concept through qualification or flight is essential
Technical Skills:
Expert in thermal analysis and simulation (Thermal Desktop, SINDA/FLUINT, ANSYS Fluent, MATLAB/Simulink, or similar)
Familiar with CAD and PLM tools (NX, Creo, CATIA) and thermal design workflows
Deep understanding of heat exchanger design, liquid and air cooling methods, thermal interface management, and insulation techniques
Experience with test planning, instrumentation setup, and thermal verification reports
Soft Skills:
Strong leadership, mentorship, and decision-making skills
Effective communicator of complex technical material to engineering, customer, and executive audiences
Strategic and systems-oriented thinker capable of balancing performance, weight, and reliability
Comfortable navigating ambiguity, managing risk, and working across disciplines