Principal Thermal Engineer - Aircraft Avionics & Thermal Systems (R3930)
Dallas Metro Area / Boston, MA / San Diego Metro Area
Aircraft Division – Mechanical /
Full Time Employee /
On-site
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 nine offices and facilities across the U.S., Europe, the Middle East, and the Asia-Pacific, Shield AI’s technology actively supports operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X, Instagram, and YouTube.
Job Description:
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 Principal Thermal Engineer at Shield AI, you will own and drive the architecture, design, and integration of avionics and aircraft-level thermal management systems, with opportunities to influence fluid systems and multidisciplinary designs.
This role is best suited for an engineer who thrives on first-principles problem solving, can set technical direction for ambiguous, open-ended challenges, and bridges technical disciplines with clear communication and leadership. You will shape designs, guide engineering teams, and deliver robust thermal solutions that meet mission-critical aerospace requirements.
What you'll do:
- Lead thermal analysis and design efforts for unmanned aerial vehicle avionics and aircraft-level thermal/fluid systems.
- Architect and validate analytical, numerical, and computational models for heat transfer and fluid flow using hand calculations and CFD tools such as FloEFD.
- Provide leadership in trade studies, system architecture decisions, and technical risk assessments.
- Define and oversee test planning, instrumentation, and data analysis to correlate models with experimental results.
- Mentor and guide cross-disciplinary teams in applying thermal/fluid fundamentals.
- Communicate technical findings through executive-level briefings, design reviews, and technical reports.
- Proactively identify program risks, propose solutions, and influence avionics and PCBA design direction.
- Represent Shield AI in technical reviews, proposals, and customer interactions.
Required qualifications:
- B.S. in Mechanical Engineering, Aerospace Engineering, or related discipline.
- Minimum 12 years of professional experience in avionics or electronics thermal engineering.
- Deep expertise in heat transfer (conduction, convection, radiation) and fluid mechanics.
- Advanced understanding of active and passive cooling solutions and their integration at the component and system level.
- Advanced knowledge 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 ability to apply first-principles reasoning to complex engineering problems.
- Strong communication and leadership skills, with experience presenting to executives and customers.
Preferred qualifications:
- M.S. or Ph.D. in a relevant engineering discipline.
- Extensive 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 aerospace thermal management.
- Experience guiding trade studies, proposals, and customer interactions in aerospace or defense programs.
- Background in multi-disciplinary system integration, spanning avionics, fluid systems, and systems engineering.
$194,094 - $291,140 a year
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Full-time regular employee offer package:
Pay within range listed + Bonus + Benefits + Equity
Temporary employee offer package:
Pay within 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, licenses 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. Please speak to your talent acquisition representative for more information.
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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.
We may use artificial intelligence (AI) tools to support parts of the hiring process, such as reviewing applications, analyzing resumes, or assessing responses. These tools assist our recruitment team but do not replace human judgment. Final hiring decisions are ultimately made by humans. If you would like more information about how your data is processed, please contact us.
