Mechanical Engineer - Thermal Analysis; RF Systems

Overview

Position Title: Mechanical Engineer - Thermal Analysis (RF Systems)

Location: Aberdeen, MD

Reports To: Hardware APM

Job Type: Full-time

Clearance Requirement: Active Secret Clearance Required;
Ability to obtain TS/SCI

Summary:

We are seeking a Mechanical Engineer with a specialized focus on the thermal management of high-power RF electronics. This role is responsible for the thermal architecture of mission-critical DoD systems, ensuring hardware survivability in extreme environments. You will utilize CST Studio Suite to bridge the gap between electromagnetic performance and thermal reality, driving the design of ruggedized enclosures from concept through environmental qualification.

Key Responsibilities:

• Advanced Multiphysics Modeling:
  Utilize CST Studio Suite to perform coupled EM-Thermal simulations. Quantify how RF losses (insertion loss, dielectric loss) translate into thermal loads.
• Electronics Packaging:
  Aid in the design and optimization of enclosures for SWaP-constrained environments, ensuring high-power components like GaN (Gallium Nitride) power amplifiers remain within junction temperature limits.
• Environmental Compliance:
  Ensure all mechanical designs meet stringent DoD survivability requirements, including thermal shock, solar radiation, and extreme ambient operating temperatures.
• Subsystem Integration:
  Direct the design of advanced cooling solutions, including micro-channel liquid cooling, phase-change materials (PCM), and high-conductivity thermal interface materials (TIMs).

Education:

• BS in Mechanical Engineering with a focus on Heat Transfer or Fluid Dynamics.
• MS is preferred.

Experience:

• 7+ years of relevant engineering experience.
• 5+ years of experience with CST Studio Suite (specifically the Thermal and Conjugate Heat Transfer solvers).

Skills:

• DoD Standards Expertise:
  Proven experience designing to and testing for:
• MIL-STD-810H:
  Environmental Engineering Considerations (Temperature, Humidity, Altitude, Vibration).
• MIL-HDBK-217:
  Reliability Prediction for Electronic Equipment.
• MIL-STD-461G:
  Requirements for the Control of Electromagnetic Interference (understanding the thermal impact of EMI shielding/gaskets).
• Advanced Materials:
  Knowledge of AlSiC, graphite foam, or synthetic diamond heat spreaders for high-flux RF components.
• Two-Phase Cooling:
  Experience with heat pipes, vapor chambers, or pumped two-phase cooling cycles for high-density electronics.
• Correlation:
  Experience using IR thermography and fiber-optic temperature sensors to validate CST models against physical prototypes.

Physical Requirements:

• Ability to travel as required.
• Standard office environment with occasional requirements to visit client sites, labs, or field environments.

• Impactful Work: Contribute to critical national security initiatives and make a real difference in protecting our nation.
• Cutting-Edge Technology: Work with the latest advancements in SIGINT and related fields.
• Career Growth: Opportunities for professional development, training, and advancement within a growing company.
• Collaborative Environment: Join a team of highly skilled and supportive engineers who are passionate about their work.
• Comprehensive Benefits: Competitive salary, generous PTO, health/dental/vision insurance, 401K matching, tuition reimbursement.

• Competitive Pay:
  Annual salary ranges from $130,000 to $180,000. Salaries depend on labor category, years of experience, education, skills relevant to the position, and type of contract.
• Benefits:
  Including Paid Time Off; 401K Contribution and Employer Match Contributions; and Medical, Dental, and Vision Coverage.
• For the full list of Luf Co Benefits, visit our website:

Position availability can vary due to dynamic, evolving contract needs. This job posting being active does not guarantee an immediately available position matching its description. This job description is intended to provide a general overview of the responsibilities and qualifications for this position. It is not an exhaustive list and may be subject to change based on the needs of the company.

Luf Co provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.

Luf Co Employees:
This position qualifies for up to a Blue Award level referral bonus. For more information, visit the Employee Portal.