Senior Engineer, Avionics Thermal Engineering; R5298

Job Description

Founded in 2015, Shield AI is a venture‑backed defense‑tech company with a mission of protecting service members and civilians with intelligent systems. Its products include Hivemind automation software and V‑BAT and X‑BAT aircraft. With offices and facilities across the U.S., Europe, the Middle East, and Asia‑Pacific, Shield AI’s technology actively supports operations worldwide.

As a Senior Thermal Engineer at Shield AI, you will own the design, analysis, and integration of aircraft avionics thermal management systems and electronics cooling. This role is best suited for an engineer who thrives on first‑principles problem solving, is comfortable with ambiguous, open‑ended challenges, and can communicate well across functions, ensuring well‑coordinated thermal management solutions.

• Own thermal solutions for unmanned aerial vehicle avionics including design, analysis, and test.
• 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.
• Drive test planning, instrumentation, and data analysis to correlate models with experimental results.
• Guide cross‑disciplinary teams in applying thermal/fluid fundamentals.
• Communicate technical findings clearly through 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 four years of professional experience in avionics or electronics thermal engineering.
• Strong expertise in heat transfer (conduction, convection, radiation) and fluid mechanics.
• Strong understanding of active and passive cooling solutions and their integration at component and system level.
• 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+).
• Experience with CAD design tools such as NX, Solid Works, or similar.
• Demonstrated experience applying first‑principles reasoning to complex engineering problems.
• Strong written and verbal communication skills.
• Proven ability to learn and adapt quickly to new tools, processes, and technical challenges in a fast‑paced, startup environment.
• M.S. in a relevant engineering discipline (preferred).
• 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.

Full‑time regular employee offer package: pay within the range listed + bonus + benefits + equity. Temporary employee offer package: pay within the range listed above + temporary benefits package (applicable after 60 days of employment). Salary compensation is influenced by a wide array of factors including but not limited to skill set, level of experience, licences and certifications, and specific work location.

All offers are contingent on a cleared background and possible reference check. Military fellows and part‑time employees are not eligible for benefits.

Shield AI is proud to be an equal opportunity workplace and is an affirmative action employer. We are committed to equal employment opportunity regardless of race, color, ancestry, religion, sex, national origin, sexual orientation, age, marital status, disability, gender identity or Veteran status. If you have a disability or special need that requires accommodation, please let us know.