Staff Thermal Analysis Engineer (Aerospace)

TL;DR

Staff Thermal Analysis Engineer (Aerospace): Designing and optimizing thermal management systems for all-electric vertical takeoff and landing aircraft with an accent on airframe thermal analysis and cooling solutions for LRUs. Focus on developing advanced CFD/FEA models and executing test campaigns to validate thermal integrity and maintain structural stability.

Location: San Jose, California, United States. Unable to provide work visa sponsorship.

Salary: $152,100 - $190,100 annually

Company

An aerospace company building an all-electric vertical takeoff and landing aircraft to advance sustainable air mobility.

What you will do

• Perform detailed thermal analysis of the airframe, accounting for external heating, solar radiation, and internal heat sources.
• Develop and implement thermal management solutions for composite structures to mitigate stress and maintain material temperature limits.
• Design and optimize cooling solutions (convection, heat pipes, liquid cooling) for actuators, flight control, and avionics.
• Create and refine advanced CFD and FEA models to simulate complex thermal scenarios and validate design assumptions.
• Plan and execute test campaigns at component, system, and aircraft levels for model correlation.
• Collaborate with Aerodynamics, Propulsion, and Battery teams to integrate thermal solutions and resolve interdependences.

Requirements

• MS or PhD in Aerospace or Mechanical Engineering or a related field.
• 5+ years of experience in thermal analysis and design within the aerospace or automotive industry.
• Strong proficiency with CFD and FEA software such as StarCCM+, Ansys Fluent, Abacus, or Nastran.
• Deep understanding of heat transfer fundamentals (conduction, convection, radiation).
• Experience with thermal testing and test-data correlation.
• Must be authorized to work in the US; no visa sponsorship is available for this position.

Nice to have

• Experience with eVTOLs, electric aircraft, or high-voltage battery systems.
• Proficiency in Python or Matlab/Simulink programming.
• Experience with CAD modeling systems like NX, CATIA, or Solidworks.
• Knowledge of version control (Git), CI/CD, and high-performance computing (HPC).
• Familiarity with airplane Part 23/25 or rotorcraft Part 27/29 certification standards.

Culture & Benefits

• Pay-for-performance culture that rewards contributions to the company's business strategy.
• Dedicated focus on cultivating an equitable, inclusive, and diverse workplace environment.
• Opportunity to solve hard problems in the field of sustainable aviation.