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 Thermal Engineer at Shield AI, you will own the design, analysis, and integration of thermal management systems for the launch and recovery system structural and electronics components. 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.
You’ll work across disciplines to ensure structural integrity, manufacturability, and mission-readiness in one of the most advanced autonomous aircraft platforms being built today. This role is ideal for an experienced thermal engineer who thrives in fast-paced, high-ownership environments and is passionate about building systems that matter.
What you'll do:
- Own thermal solutions for the autonomous aircraft launch and recovery system
- Develop and validate analytical, numerical, and computational models for heat transfer and fluid flow using hand calculations and CFD tools such as FloEFD.
- Prototype, test, and iterate mechanism designs for functionality and reliability
- 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.
- Proactively identify risks, propose solutions, and influence mechanical, electrical and/or PCBA design direction.
- Collaborate with mechanical, electrical, avionics, flight controls, manufacturing, and test teams
- Support pre-production builds, prototype integration, and ground/flight testing on the pathway to production and field deployment
- Participate in design reviews, architecture discussions, and technical decision-making forums related to structural systems.
- Identify opportunities to improve design processes, configuration management, and team workflows for increased engineering velocity and design quality.
Required qualifications:
- B.S. in Mechanical Engineering, Aerospace Engineering, or related discipline.
- 2+ years of professional experience in 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, SolidWorks, 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.
- A demonstrated record of working hard, being trustworthy, holding yourself to high standards, and being kind to others
- Ability to obtain a S//SAR level security clearance desired.
Preferred qualifications:
- M.S. in a relevant engineering discipline.
- Hands-on experience with thermal and fluid system testing, instrumentation, and validation.
- Knowledge of materials and manufacturing methods relevant to thermal management
- MIL-STD-810, structural, or actuated mechanism testing experience
- Ability to thrive in startup, R&D, or defense innovation environments
Skills Required
- B.S. in Mechanical Engineering, Aerospace Engineering, or related discipline.
- 2+ years of professional experience in 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, SolidWorks, 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.
- A demonstrated record of working hard, being trustworthy, holding yourself to high standards, and being kind to others.
- Ability to obtain a S//SAR level security clearance (desired).
- M.S. in a relevant engineering discipline.
- Hands-on experience with thermal and fluid system testing, instrumentation, and validation.
- Knowledge of materials and manufacturing methods relevant to thermal management.
- MIL-STD-810, structural, or actuated mechanism testing experience.
- Ability to thrive in startup, R&D, or defense innovation environments.
What the Team is Saying
Shield AI Compensation & Benefits Highlights
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Healthcare Strength — Company materials describe excellent medical, dental, and vision coverage alongside a mental‑health EAP. Site perks such as an onsite gym in DC and a gym discount in San Diego support a health‑focused offering.
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Retirement Support — Careers materials highlight a 401(k) with company match as part of the standard package. A Total Rewards overview emphasizes retirement features within a broader, transparent compensation view.
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Career-Linked Recognition & Rewards — Compensation for in‑demand technical and senior go‑to‑market roles is described as competitive, with visible engineering ranges and top‑end packages. This points to meaningful upside tied to role, level, and scarce skills.
Shield AI Insights
What We Do
Founded in 2015, Shield AI is a venture-backed deep-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include the V-BAT and X-BAT aircraft, Hivemind Enterprise, and the Hivemind Vision product lines. With offices and facilities across the U.S., Europe, the Middle East, and the Asia-Pacific, Shield AI’s technology actively supports operations worldwide.
Why Work With Us
What makes Shield AI special is our people. We unlock the power of autonomy, and in the face of overwhelming odds and challenges, we find ways to win and make a difference for our customers. We bring together software, AI, and aerospace engineering disciplines to deploy the most intelligent aviation capabilities in the world.
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Shield AI Offices
Hybrid Workspace
Employees engage in a combination of remote and on-site work.
