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

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-BAT aircraft, 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

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