Job Description:
Are you a passionate and innovative thermal engineer looking to help develop state of the art aircraft? 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 Senior Staff Thermal Engineer at Shield AI, you will lead the design, analysis, and integration of aircraft avionics thermal management systems. We are designing a high voltage, high power system using custom power electronics and energy storage. 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.
What you'll do:
- 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
Required qualifications:
- 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.
Skills Required
- B.S. in Mechanical Engineering, Aerospace Engineering, or related discipline
- Minimum 7 years 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 system-level integration
- Deep understanding of thermal management elements: TIMs, spreaders, heat sinks, vapor chambers, heat pipes, 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 experience leading technical discussions and presentations
- 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
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.
