The goal of this work is to develop a predictive method for evaluating material performance under thermal runaway conditions due to escaping gas and particles at materials used in venting structures. To achieve this, a neural network will be designed, trained, and applied to new materials. The neural network will be trained and validated using existing experimental and simulation data. The generated evaluation data will be compared with results from classical substitute and cell tests to evaluate the performance and reliability of the developed approach. Based on the obtained data, characteristic parameters for evaluating material failure under thermal runaway conditions will be identified and derived.

In the first step, a systematic literature review will be conducted on existing experimental, analytical, and simulation methods for evaluating fire protection materials in the thermal runaway context. Based on this, a suitable model for evaluating material performance in the context of thermal runaway will be developed, trained, and implemented. The model will be validated using experimental data to assess its predictive accuracy and robustness. Finally, the applicability of the developed approach and potential opportunities for further development will be critically discussed.

Key tasks:

• Conduct a systematic literature review on existing experimental, analytical, and simulation methods for evaluating fire protection materials in the thermal runaway context.

• Design, train, and implement a neural network for predictive evaluation of material performance under thermal runaway conditions.

• Evaluate and analyse experimental and simulation data to validate the model.

• Compare generated evaluation data with results from classical substitute and cell tests.

• Identify and derive characteristic parameters for evaluating material failure under thermal runaway conditions.

• Critically discuss the applicability of the developed approach and potential opportunities for further development.

Requirements:

• Bachelor's or master's degree in computer science, mechanical engineering, electrical engineering, or a related field.

• Experience in machine learning and deep learning.

• Familiarity with Python programming language and relevant libraries.

• Good understanding of thermal runaway phenomena and fire protection materials.

• Excellent communication and teamwork skills.

• Ability to work independently and manage multiple tasks.

Preferred skills:

• Experience with neural networks and deep learning frameworks such as TensorFlow or PyTorch.

• Familiarity with simulation software such as ANSYS or COMSOL.

• Knowledge of thermal analysis and heat transfer.

• Experience with data analysis and visualisation tools such as Matplotlib or Seaborn.

• Familiarity with version control systems such as Git.

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Key responsibilities include:

• Aerodynamics design of unmanned air vehicles/missiles at conceptual, preliminary, and detailed design maturities
• Aerodynamics analysis of unmanned air vehicles, using both low and high order methods, including analysis tool development and improvement as needed
• Stability and control analysis
• Trajectory optimization for performance analysis, vehicle conceptual trades, and sensitivities
• Aerothermodynamic analysis of flight vehicles in high-speed environments
• Aircraft performance modeling and simulation
• Aerodynamic loads generation
• Wind tunnel test planning, execution, and analysis
• Flight test planning, execution, and analysis

Required qualifications include:

• BS or higher degree in Aerospace Engineering
• Experience with a variety of aerodynamic analysis techniques including hand calculations, lower-order codes, and computational fluid dynamics (CFD)
• Strong programming skills in higher-level languages (e.g., MATLAB, Python) for internal tool development in a version-controlled environment
• Experience preparing formal documentation (i.e., specifications, test procedures, technical reports, etc.)
• Passion for defending the United States and her allies
• Ability to obtain and hold a U.S. Top Secret security clearance

Preferred qualifications include:

• StarCCM+ experience
• Experience evaluating external aerodynamics characteristics of a vehicle in the supersonic or hypersonic flow regime
• Experience with aerothermal analysis
• Experience leveraging trajectory optimization software for performance analysis, vehicle conceptual trades, and/or sensitivities
• Knowledge of high-speed aerodynamic laminar, transitional, and turbulent simulation techniques
• Experience with chemical kinetics modeling and simulation
• Experience with combustion computational fluid dynamics and a foundational understanding of compressible flow
• Active U.S. Secret security clearance

US Salary Range: $146,000-$194,000 USD

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A successful candidate will have experience with military specifications and wearable systems. They should be able to pursue prototyping and evaluation efforts with a high degree of autonomy meeting stringent SWAP-C requirements while balancing human factors and comfort with packaging needs.

Responsibilities: Design and develop mechanical systems for wearable devices, including traditional and additive manufacturing from prototype through production with metallics and composites. Ergonomics and Human Factors: Designing for comfort, fit, and usability to ensure the wearable devices are effective for prolonged wear in tactical environments. Structural/Thermal Analysis: Ability to perform first-order analyses to inform trade studies and concept designs. Manufacturing Processes: Knowledge of techniques for fabricating and assembling materials, including molding, laminating, and machining. Thermal and Environmental Considerations: Understanding how temperature, humidity, and other environmental factors affect materials and performance.

Qualifications & Critical Competencies: BS, M.Eng, MS or PhD in an engineering field. 1-6 years Mechanical Engineering Experience. CAD skills (any platform) and ability to manage complex parts and assemblies, and produce high-quality engineering drawings. High competencies with: Detailed mechanical design for traditional and additive manufacturing from prototype through production with metallics and composites. Ergonomics and Human Factors: Designing for comfort, fit, and usability to ensure the wearable devices are effective for prolonged wear in tactical environments. Structural/Thermal Analysis: Ability to perform first-order analyses to inform trade studies and concept designs. Manufacturing Processes: Knowledge of techniques for fabricating and assembling materials, including molding, laminating, and machining. Thermal and Environmental Considerations: Understanding how temperature, humidity, and other environmental factors affect materials and performance.

Preferred Qualifications: Consumer electronics packaging and design, design for cameras, displays, SoC integration, and ruggedization. Experience with a military qualification program, including a deep understanding of MIL-STD requirements. Experience with NX/Teamcenter, including FEA extensions. Experience rapid prototyping and iterating with 3D printed assets.

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Key responsibilities include:

• Executing rapid evaluation of engineering concepts in a wide range of fields
• Performing trade studies and physics-based analysis of blue-sky engineering problems
• Designing, implementing, and testing complex electro-mechanical systems
• Leading design reviews, running analysis, visiting vendors, defining and executing hardware test plans
• Building prototypes, analyzing failures, and transitioning successful projects into production
• Supporting critical hardware demonstrations with customers as needed
• Traveling to test sites as needed

Required qualifications include:

• Experience in an immersive technical project (collegiate project teams or professional settings)
• 3+ years of mechanical design experience in a professional setting
• Experience designing mechanical parts (CAD) and understanding of manufacturing methods (machining, sheet metal, composites, 3D printing, injection molding, composite lamination, etc)
• Ability to read, interpret, and manipulate schematics, wiring diagrams, and layouts
• High competence with, and fluid use of, engineering first principles
• BS, MS, or PhD in an engineering field, or equivalent work experience
• Eligible to obtain and maintain an active U.S. Secret security clearance

Preferred qualifications include:

• Experience developing aircraft subsystem layouts, performing architectural trade studies, and evaluating vendor performance data
• Competency in engineering analysis, including structural, thermal, and electrical
• Hands-on prototyping (soldering, board assembly, harnessing)
• Outstanding leadership and interpersonal skills
• Familiarity with designing for rugged environments
• Experience integrating electrical and mechanical subsystems (sensors, payloads, weapons, etc.) onto air vehicles
• Experience in developing a variety of electronics hardware products (UAVs, wearables, firearms, high power electric propulsion, optical systems, or other complex mechanisms)
• Practical experience with electrical engineering tools (Oscilloscopes, power supplies, electronic loads, multimeters)
• Understanding of MIL-STD requirements such as MIL-STD-1275, MIL-STD-461, MIL-STD-810, MIL-DTL-38999

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The ideal candidate will have 5+ years of mechanical engineering experience in advanced air vehicle programs. They will be familiar with hypersonic missile systems and military standards. They will have hands-on experience integrating electrical and mechanical subsystems into high-speed air vehicles. They will be proficient in designing mechanical parts using CAD software and a strong understanding of manufacturing methods, including machining, sheet metal work, composites, 3D printing, injection molding, and composite lamination. They will have a strong understanding of mechanical engineering fundamentals and first principles. They will hold a BS or higher degree in Mechanical, Aerospace, or Electrical Engineering. They will be eligible to obtain and maintain an active U.S. Secret security clearance.

Preferred qualifications include experience using Siemens NX and Teamcenter software. Expertise in air vehicle subsystem layouts, architectural trade studies, and vendor data evaluations is also desirable. An active DoD Top Secret security clearance is preferred. Proficiency in advanced engineering analysis, including structural, thermal, and/or electrical domains, is also a plus.

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The ideal candidate will have a BS, M.Eng, MS or PhD in an engineering field, 1-6 years Mechanical Engineering Experience, and CAD skills (any platform) and ability to manage complex parts and assemblies, and produce high-quality engineering drawings. They should also have high competencies with detailed mechanical design for traditional and additive manufacturing from prototype through production with metallics and composites, ergonomics and human factors, structural/thermal analysis, manufacturing processes, and thermal and environmental considerations.

Preferred qualifications include consumer electronics packaging and design, design for cameras, displays, SoC integration, and ruggedization, experience with a military qualification programs including a deep understanding of MIL-STD requirements, experience with NX/Teamcenter, including FEA extensions, and experience rapid prototyping and iterating with 3D printed assets.

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We're looking for a Senior Staff Electromechanical Engineer to join our team, focused on the design and integration of avionics systems and driving designs from concept to production.

Responsibilities:

• Design complex electro-mechanical solutions for avionics packaging, electrical interconnects, thermal management, and aircraft integration
• Perform structural, preliminary thermal, and modal analyses for avionics to ensure survivability in harsh environments
• Ensure avionics meet performance, safety, environmental, and EMI/EMC compliance standards, including DO-160, DO-254, DO-178C, MIL-STD-810, and MIL-STD-461
• Own your design work from concept to reviews through system validation, failure analysis, and flight test readiness

Requirements:

• B.S. and/or MS in Mechanical/Aerospace Engineering
• 10+ years of experience in mechanical & electrical equipment design for aerospace, including harness integration and mechanical component design
• Expertise in CAD software (NX, SolidWorks, CATIA, or similar) for 3D modeling, drawing creation, and system layout
• Familiarity with eCAD software (Altium, Cadence, Allegro), and harness design software (Capital, Zuken)
• Experience working with electrical engineers to define PCB constraints, develop circuit cards, and care for all the mechanical interfaces
• Familiarity with the PCB layout process and advanced manufacturing methods
• Experience with finite element analysis (FEA), thermal analysis, and fatigue/lifecycle testing

Benefits:

• Pay within range listed ($166,632 - $249,948 a year)
• Bonus
• Benefits
• Equity

Temporary employee offer package: Pay within range listed above + temporary benefits package (applicable after 60 days of employment)

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As a Thermal Engineer at Shield AI, you will:

• Own thermal analysis and design efforts for unmanned aerial vehicle avionics, including custom power electronics
• Develop and validate analytical, numerical, and computational models for heat transfer and fluid flow using hand calculations and CFD tools such as FloEFD
• Provide input to trade studies, system architecture decisions, and risk assessments
• Assist cross-functional teams designing power electronic circuits and environmental enclosures
• Contribute to design requirements that impact circuit part selection, board layout, material selection, and other design aspects
• 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

Required qualifications:

• B.S. in Mechanical Engineering, Aerospace Engineering, or related discipline
• Internship or engineering club experience in avionics or electronics thermal engineering
• Knowledge of heat transfer (conduction, convection, radiation) and fluid mechanics
• Familiarity with thermal analysis and CFD tools (e.g., ANSYS Icepak, FloEFD, STAR-CCM+)
• Experience with CAD design tools such as NX, SolidWorks, or similar
• Demonstrated experience applying first-principles reasoning to engineering problems
• Strong written and verbal communication skills, with a track record of leading technical discussions and presenting to stakeholders

Salary compensation is influenced by a wide array of factors including but not limited to skill set, level of experience, licenses and certifications, and specific work location.

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We are seeking a Senior Staff Mechanical Design Engineer to lead the design, development, and testing of systems to expand and scale V-BAT's capabilities and mission impact. This role is instrumental in creating robust, field-deployable systems that enable aircraft operations, maintenance, and sustainment in military environments.

Key responsibilities include:

Designing and developing mechanical systems for V-BAT, including payloads, power/propulsion designs, transport structures, launch & recovery systems, and more. Creating detailed CAD models, drawings, and specifications for manufacturing and assembly. Conducting structural, thermal, and fatigue analysis to ensure durability and reliability of systems in field environments. Collaborating with cross-functional teams to integrate designs with aircraft systems and mission operations. Performing trade studies and system optimization to enhance portability, ruggedness, and maintainability of support systems. Overseeing prototyping, testing, and validation of designs to meet military and aviation standards. Developing technical documentation, test procedures, and support manuals for field operations. Working with suppliers and manufacturing partners to ensure cost-effective production and sustainment of designed systems. Supporting flight test campaigns by providing engineering support for ground systems and test operations.

Requirements include:

8+ years of experience in mechanical design for aerospace, ground support equipment, or heavy industrial systems. Expertise in CAD software (SolidWorks, CATIA, NX, or similar) for 3D modeling, drawing creation, and system layout. Strong background in structural analysis, material selection, and manufacturing processes for ruggedized systems. Experience designing deployable, transportable, and field-ready aerospace support equipment. Knowledge of MIL-STD design requirements for aerospace ground support systems. Experience with finite element analysis (FEA), thermal analysis, and fatigue/lifecycle testing. Ability to work in a fast-paced, agile development environment with evolving priorities.

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As a Staff Thermal Engineer, you will contribute to thermal analysis and design efforts for unmanned aerial vehicle avionics and thermal/fluid systems. You will develop and validate analytical, numerical, and computational models for heat transfer and fluid flow using hand calculations and CFD tools such as FloEFD. You will drive test planning, instrumentation, and data analysis to correlate models with experimental results.

Key responsibilities include:

• Contributing to thermal analysis and design efforts for unmanned aerial vehicle avionics and thermal/fluid systems
• Developing and validating analytical, numerical, and computational models for heat transfer and fluid flow using hand calculations and CFD tools such as FloEFD
• Driving test planning, instrumentation, and data analysis to correlate models with experimental results
• Communicating technical findings clearly through executive-level briefings, design reviews, and written reports

Requirements include:

• 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
• 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

Preferred qualifications include:

• 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

Salary: $136,730 - $205,096 a year

Benefits: Pay within range listed + Bonus + Benefits + Equity

Note: Salary compensation is influenced by a wide array of factors including but not limited to skill set, level of experience, licenses and certifications, and specific work location.

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This role is instrumental in creating robust, field-deployable support systems that enable aircraft operations, maintenance, and sustainment in military environments.

Key responsibilities include:

• Designing and developing mechanical systems for GSE, including power units, transport structures, launch & recovery systems, and maintenance tools.
• Creating detailed CAD models, drawings, and specifications for manufacturing and assembly.
• Conducting structural, thermal, and fatigue analysis to ensure durability and reliability of GSE in field environments.
• Collaborating with cross-functional teams to integrate GSE with aircraft systems and mission operations.
• Performing trade studies and system optimization to enhance portability, ruggedness, and maintainability of support systems.
• Overseeing prototyping, testing, and validation of GSE designs to meet military and aviation standards.
• Developing technical documentation, test procedures, and support manuals for field operations.
• Working with suppliers and manufacturing partners to ensure cost-effective production and sustainment of GSE.

Requirements include:

• 7+ years of experience in mechanical design for aerospace, ground support equipment, or heavy industrial systems.
• Expertise in CAD software (SolidWorks, CATIA, NX, or similar) for 3D modeling, drawing creation, and system layout.
• Strong background in structural analysis, material selection, and manufacturing processes for ruggedized systems.
• Experience designing deployable, transportable, and field-ready aerospace support equipment.
• Knowledge of MIL-STD design requirements for aerospace ground support systems.
• Experience with finite element analysis (FEA), thermal analysis, and fatigue/lifecycle testing.
• Ability to work in a fast-paced, agile development environment with evolving priorities.

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This role is instrumental in creating robust, field-deployable support systems that enable aircraft operations, maintenance, and sustainment in military environments.

Key responsibilities include:

• Designing and developing mechanical systems for GSE, including power units, transport structures, launch & recovery systems, and maintenance tools.
• Creating detailed CAD models, drawings, and specifications for manufacturing and assembly.
• Conducting structural, thermal, and fatigue analysis to ensure durability and reliability of GSE in field environments.
• Collaborating with cross-functional teams to integrate GSE with aircraft systems and mission operations.
• Performing trade studies and system optimization to enhance portability, ruggedness, and maintainability of support systems.
• Overseeing prototyping, testing, and validation of GSE designs to meet military and aviation standards.
• Developing technical documentation, test procedures, and support manuals for field operations.
• Working with suppliers and manufacturing partners to ensure cost-effective production and sustainment of GSE.

Requirements include:

• 7+ years of experience in mechanical design for aerospace, ground support equipment, or heavy industrial systems.
• Expertise in CAD software (SolidWorks, CATIA, NX, or similar) for 3D modeling, drawing creation, and system layout.
• Strong background in structural analysis, material selection, and manufacturing processes for ruggedized systems.
• Experience designing deployable, transportable, and field-ready aerospace support equipment.
• Knowledge of MIL-STD design requirements for aerospace ground support systems.
• Experience with finite element analysis (FEA), thermal analysis, and fatigue/lifecycle testing.
• Ability to work in a fast-paced, agile development environment with evolving priorities.

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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.

Responsibilities:

• Own thermal analysis and design efforts for unmanned aerial vehicle avionics including custom power electronics
• Develop and validate analytical, numerical, and computational models for heat transfer and fluid flow using hand calculations and CFD tools such as FloEFD
• Provide technical leadership in trade studies, system architecture decisions, and risk assessments
• Lead cross-functional teams designing power electronic circuits and environmental enclosures. Provide design requirements that impact circuit part selection, board layout, material selection, and other design aspects
• Drive test planning, instrumentation, and data analysis to correlate models with experimental results
• Mentor junior engineers and guide cross-disciplinary teams in applying thermal/fluid fundamentals
• 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

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This role requires deep expertise in mechanical design, structural analysis, and aerospace ground systems. You will work closely with engineering, manufacturing, and flight operations teams to develop innovative support solutions that enhance mission effectiveness and operational efficiency.

Responsibilities:

• Design and develop mechanical systems for a Launch and Recovery System, including power units, transport structures, launch & recovery functions, and maintenance tools.
• Create detailed CAD models, drawings, and specifications for manufacturing and assembly.
• Conduct structural, thermal, and fatigue analysis to ensure durability and reliability of launcher systems in field environments.
• Collaborate with cross-functional teams to integrate launcher with aircraft systems and mission operations.
• Perform trade studies and system optimization to enhance portability, ruggedness, and maintainability of support systems.
• Oversee prototyping, testing, and validation of launcher designs to meet military and aviation standards.
• Develop technical documentation, test procedures, and support manuals for field operations.
• Work with suppliers and manufacturing partners to ensure cost-effective production and sustainment of launcher system.
• Support flight test campaigns by providing engineering support for ground and test operations.

Required qualifications:

• 10+ years of experience in mechanical design for aerospace, ground support equipment, or heavy industrial systems.
• Expertise in CAD software (SolidWorks, CATIA, NX, or similar) for 3D modeling, drawing creation, and system layout.
• Strong background in structural analysis, material selection, and manufacturing processes for ruggedized systems.
• Experience designing deployable, transportable, and field-ready aerospace support equipment.
• Knowledge of MIL-STD design requirements for aerospace systems.
• Experience with finite element analysis (FEA), thermal analysis, and fatigue/lifecycle testing.
• Ability to work in a fast-paced, agile development environment with evolving priorities.

Preferred qualifications:

• Experience designing UAS or military aircraft ground support equipment.
• Knowledge of power distribution, hydraulics, and environmental control systems for aerospace applications.
• Experience with DoD acquisition, sustainment, and field deployment strategies.
• Prior experience supporting military aircraft maintenance and sustainment operations.
• Active Secret or Top Secret clearance (or ability to obtain one).

Salary: $160,000 - $240,000 a year

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We are seeking a Senior Engineer, Mechanical Design to support the design, development, and testing of systems that expand and scale V-BAT's operational capabilities. This role contributes to the creation of robust, field-deployable systems that enable aircraft operations, maintenance, and sustainment in military environments.

You will apply strong mechanical design fundamentals to develop reliable, manufacturable hardware while collaborating closely with engineering, manufacturing, and flight operations teams.

Responsibilities:

• Design and develop mechanical systems and subsystems for V-BAT, including payload integrations, propulsion-related components, transport structures, and launch & recovery support equipment.
• Create detailed CAD models, drawings, and release packages for manufacturing and assembly.
• Perform structural, thermal, and fatigue analyses to validate performance in rugged field environments.
• Support integration efforts across aircraft systems and mission operations teams.
• Conduct trade studies to optimize weight, durability, manufacturability, and maintainability.
• Support prototype builds, testing, and validation efforts to meet aviation and military standards.
• Develop technical documentation including test plans, procedures, and field support materials.
• Partner with suppliers and manufacturing teams to ensure design intent, cost targets, and production readiness.
• Provide engineering support during ground and flight test operations as needed.

Qualifications:

• 5 years of experience in mechanical design for aerospace, ground support equipment, or related ruggedized hardware systems.
• Proficiency in CAD software (SolidWorks, CATIA, NX, or similar) for 3D modeling and drawing creation.
• Strong foundation in structural design, material selection, and manufacturing processes.
• Experience designing hardware for field, transport, or operational environments.
• Familiarity with engineering analysis methods such as FEA, thermal analysis, and fatigue evaluation.
• Ability to work effectively in a fast-paced development environment with evolving priorities.

Preferred Qualifications:

• Experience supporting UAS or military aircraft systems.
• Familiarity with MIL-STD requirements and environmental qualification testing.
• Exposure to power distribution, hydraulics, or aerospace support systems.
• Experience working with external suppliers or contract manufacturers.
• Active Secret or Top Secret clearance (or ability to obtain one).

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You will work the director of engineering in a deputy capacity to support collaboration across engineering sites, align technical leaders, create mentorship opportunities for junior engineers, and assist in leveling engineering resources across vehicles and programs.

You will set the bar for excellence through technical demonstration, guidance, and mentorship.

Responsibilities:

• Lead a team designing complex electro-mechanical solutions for flight critical avionics systems. This includes packaging, electrical interconnects, thermal management, and integration of designs into the X-BAT aircraft
• Drive structural, thermal, and modal analyses for electromechanical systems to ensure survivability in harsh environments
• Work cross-functionally with electrical engineering, supply chain, supplier development engineering, manufacturing, and other mechanical engineering teams
• Ensure avionics meet performance, safety, environmental, and EMI/EMC compliance standards on a long-term path to airworthiness certification
• Lead by example - own work from design, verification, and through production

Requirements:

• B.S. in Mechanical/Aerospace Engineering
• 10+ years of experience in mechanical & electrical equipment design for aerospace, including harness integration and mechanical component design
• Expertise in CAD software (NX, SolidWorks, CATIA, or similar) for 3D modeling, drawing creation, and system layout. Familiarity with eCAD software (Altium, Cadence, Allegro), and harness design software (Capital, Zuken)
• Experience working with electrical engineers to define PCB constraints, develop circuit cards, and care for all the mechanical interfaces
• Experience with finite element analysis (FEA), thermal analysis, and fatigue/lifecycle testing
• Experience working directly with fabrication shops, contract manufacturers, and suppliers.
• Ability to work in a fast-paced, agile development environment with evolving priorities
• A demonstrated record of working hard, being trustworthy, holding yourself to high standards, and being kind to others

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As the Principal Aircraft Thermal Engineer, you will lead thermal analysis and characterization efforts for unmanned aerial vehicle aircraft-level thermal systems. You will architect and validate analytical, numerical, and computational models for heat transfer and fluid flow using hand calculations, finite difference methods, and CFD tools such as FloEFD.

You will provide leadership in trade studies, system architecture decisions, requirements generation, and technical risk assessments. You will define and oversee test planning, instrumentation, and data analysis to correlate models with experimental results.

You will mentor and guide cross-disciplinary teams in applying thermal/fluid fundamentals. You will communicate technical findings through executive-level briefings, design reviews, and technical reports.

Key responsibilities include:

• Leading thermal analysis and characterization efforts for unmanned aerial vehicle aircraft-level thermal systems
• Architecting and validating analytical, numerical, and computational models for heat transfer and fluid flow
• Providing leadership in trade studies, system architecture decisions, requirements generation, and technical risk assessments
• Defining and overseeing test planning, instrumentation, and data analysis
• Mentoring and guiding cross-disciplinary teams
• Communicating technical findings through executive-level briefings, design reviews, and technical reports

Requirements include:

• B.S. in Mechanical Engineering, Aerospace Engineering, or related discipline
• Minimum 12 years of professional experience in avionics or electronics thermal engineering
• Deep expertise in heat transfer (conduction, convection, radiation) and fluid mechanics
• Advanced understanding of active and passive cooling solutions and their integration at the component and system level
• Proficiency with thermal analysis and CFD tools (e.g., FloEFD, STAR-CCM+)
• Proficiency with CAD design tools such as NX, SolidWorks, or similar
• Demonstrated ability to apply first-principles reasoning to complex engineering problems
• Ability to learn new and cutting-edge materials knowledge and thermal management techniques from a variety of sources (technical papers, text books, etc.) and apply it to the development of advanced thermal management design
• Strong communication and leadership skills, with experience presenting to executives and customers

Preferred qualifications include:

• M.S. or Ph.D. in a relevant engineering discipline
• Extensive experience with high-altitude aircraft thermal management, analysis, and 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 aerospace thermal management
• 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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In this role, you will shape the propulsion test strategy, direct complex engine and hover test campaigns, and provide technical leadership across the program to ensure safe and rapid development of a next-generation autonomous aircraft.

The ideal candidate brings deep expertise in jet propulsion testing, developmental flight test operations, to include mission control room operations, and high-energy ground testing.

You will work closely with propulsion engineers, flight test teams, autonomy developers, instrumentation specialists, and safety organizations to define test objectives, assess risk, and deliver the data required to advance the aircraft through its test envelope.

This is a high-impact role for a technical leader who thrives in fast-paced, experimental environments and who wants to help define the future of autonomous aviation.

Responsibilities:

• Support engine, hover, static, and integrated propulsion test campaigns for X-BAT including planning, execution, and post-test analysis.
• Advise on propulsion system readiness and define test objectives, test point development, build up approach, success criteria, and instrumentation requirements.
• Develop and review test procedures, hazard analyses, run cards, and safety documentation for high-energy test operations.
• Provide technical oversight during engine runs, hover tests, transition testing, and propulsion-autonomy integration events.
• Serve as a propulsion subject-matter expert during Test Readiness Reviews (TRRs), Test Hazard Analyses (THAs), and Operational Risk Management (ORM) assessments
• Support root-cause investigations related to propulsion performance, engine controls, thermal behavior, vibration, and integration issues.
• Partner with Autonomy and Avionics teams to evaluate propulsion-related interactions such as thrust control logic, response lags, fail-safes, and emergency behaviours.
• Collaborate with Instrumentation Engineering to ensure data quality, test post process analysis, reporting, timing, and fidelity across propulsion channels.
• Support field deployments, remote test sites, and intensive test cycles as required to meet program schedules.

Qualifications:

• Bachelor's degree in Aerospace Engineering, Mechanical Engineering, or related technical discipline.
• 8+ years of experience in propulsion testing for jet engines, VTOL systems, unmanned aircraft, or developmental flight test programs.
• Demonstrated expertise executing and analysing engine tests, hover/transition events, and integrated propulsion-airframe testing.
• Strong understanding of engine controls, FADEC systems, thrust measurement, thermal analysis, and vibration/loads behaviour.
• Experience writing and reviewing high-energy test procedures, readiness documentation, and hazard analyses.
• Proven ability to operate safely and decisively in fast-paced test environments.
• Excellent communication skills and demonstrated performance in multidisciplinary engineering organisations.
• Ability to travel and support extended field test deployments.

Preferred Qualifications:

• Master's degree or higher in Aerospace or Mechanical Engineering.
• Experience with tail-sitter, VTOL, or thrust-vectoring propulsion systems.
• Background in autonomy-powered aircraft, propulsion-system modelling, or propulsion-flight-control integration.
• Familiarity with IRIG, PCM, instrumentation requirements, and high-rate telemetry data.
• Experience supporting complex investigations or leading propulsion technical review boards.
• Prior involvement in developmental or experimental flight test programmes.
• Experience with compressed-air starts, engine-health monitoring systems, or high-temperature structural analysis.

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