ZipRecruiter
Mechanical Thermal Analysis Engineer
ZipRecruiter, Simi Valley, California, United States, 93097
Overview
ALTEN Technology USA, an engineering company, partners with clients to bring groundbreaking ideas to life across aerospace, medical devices, robotics, automotive, EVs, rail, and more. With 3,000+ experts in North America and a global network of 57,000+ engineers, we deliver across the entire product development cycle from consulting to full project outsourcing. When you join ALTEN Technology USA, you’ll collaborate on challenging engineering challenges with mentorship, career growth opportunities, and comprehensive benefits, in a culture that values and supports employees. Position : Mechanical Thermal Analysis Engineer for UAV/UAS platforms Responsibilities
Lead or support thermal analysis efforts for UAV/UAS systems, including propulsion heating, avionics cooling, fuselage blanketing, and environmental conditioning. Develop and run 3D FEA and CFD models using ANSYS Icepak and other CAE tools to predict thermal behavior and guide design trade-offs. Perform heat sink design and optimization for propulsion systems, electronic components, and structural elements. Assess technical risks for ground and flight testing of high-flying UAVs, including thermal limits, heat rejection, and altitude effects on performance. Support environmental requirements definition and compliance (thermal, vibration, altitude, humidity). Develop and execute thermal test plans, procedures, and instrumentation setups to validate designs in laboratory and field environments. Analyze test data, generate reports, and recommend corrective actions or design refinements. Collaborate with multidisciplinary teams to integrate thermal management strategies into fuselage design, propulsion systems, and avionics packaging. Create and maintain mechanical drawings, documentation, and product structures including BOMs and design trees. Support project planning and coordination, including subcontractor management where thermal subsystems or analyses are outsourced. Basic Qualifications (Required Skills & Experience)
Minimum 5+ years of relevant technical experience in thermal/mechanical engineering for UAVs, aerospace platforms, or advanced electronic systems. Proficiency in thermal modeling and simulation using ANSYS Icepak, ANSYS Mechanical, or equivalent FEA/CFD tools. Experience performing 3D FEA/CFD analyses for structural and thermal problems, including propulsion heating, fuselage insulation/blanketing, and avionics cooling. Strong knowledge of thermal management tradeoffs and materials properties, including adhesives, coatings, and insulating materials for extreme environments. Experience with heat sink design, airflow analysis, and environmental conditioning systems. Familiarity with environmental qualification requirements (DO-160, MIL-STD, or equivalent). Skilled in test and measurement techniques including thermal instrumentation, heat flux measurement, and environmental chamber testing. Proficiency in CAD tools (SolidWorks or equivalent) for mechanical modeling. Strong documentation skills, including requirements definition, BOM management, and technical risk assessment reporting. Qualifications
Experience applying RTCA DO-160, MIL-STD-810, or MIL-STD-1540 for environmental and thermal qualification of aerospace systems. Background in UAV/UAS thermal management, including propulsion heat rejection, fuselage insulation/blanketing, and avionics packaging strategies. Hands-on experience with thermal vacuum testing, altitude chambers, and propulsion thermal stress testing. Knowledge of fuel system thermal behavior and its impact on propulsion efficiency in UAV/UAS. Experience leading multidisciplinary design reviews with a focus on thermal performance and environmental survivability. Familiarity with model-based systems engineering (MBSE) tools such as Cameo for integrating thermal subsystem requirements into the overall UAV system design. Prior experience working with defense contractors, aerospace primes, or UAV/UAS OEMs on thermal or environmental subsystems. Salary Range: $140,000-170,000 The actual salary offered depends on location, candidate's knowledge, qualifications, skills, education, training, and experience. Note:
For remote/hybrid and/or California, Colorado, Maryland, Connecticut, Illinois, Minnesota, Vermont, Massachusetts, Nevada, New York, Rhode Island, Washington state, Cincinnati (OH), Jersey City (NJ), Toledo (OH) based roles, applicants must meet requirements. Compliance and Equal Opportunity
ALTEN Technology is an Equal Opportunity Employer. Our policy is to extend opportunities to qualified applicants and employees on an equal basis regardless of race, color, religion, sex, national origin, disability, veteran status, or other protected status. Important Notice
Job seekers should beware of scams. See our careers page for information about our recruiting process. Compliance Notice:
ALTEN USA is a federal contractor subject to VECRA and EO 11246. We are an Equal Opportunity Employer and consider all qualified applicants without regard to race, color, religion, sex, national origin, disability, veteran status, or other protected status. Drug Screening Requirement:
As a federal contractor, ALTEN USA maintains a drug-free workplace. All candidates selected for employment will be required to complete a pre-employment drug screening.
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ALTEN Technology USA, an engineering company, partners with clients to bring groundbreaking ideas to life across aerospace, medical devices, robotics, automotive, EVs, rail, and more. With 3,000+ experts in North America and a global network of 57,000+ engineers, we deliver across the entire product development cycle from consulting to full project outsourcing. When you join ALTEN Technology USA, you’ll collaborate on challenging engineering challenges with mentorship, career growth opportunities, and comprehensive benefits, in a culture that values and supports employees. Position : Mechanical Thermal Analysis Engineer for UAV/UAS platforms Responsibilities
Lead or support thermal analysis efforts for UAV/UAS systems, including propulsion heating, avionics cooling, fuselage blanketing, and environmental conditioning. Develop and run 3D FEA and CFD models using ANSYS Icepak and other CAE tools to predict thermal behavior and guide design trade-offs. Perform heat sink design and optimization for propulsion systems, electronic components, and structural elements. Assess technical risks for ground and flight testing of high-flying UAVs, including thermal limits, heat rejection, and altitude effects on performance. Support environmental requirements definition and compliance (thermal, vibration, altitude, humidity). Develop and execute thermal test plans, procedures, and instrumentation setups to validate designs in laboratory and field environments. Analyze test data, generate reports, and recommend corrective actions or design refinements. Collaborate with multidisciplinary teams to integrate thermal management strategies into fuselage design, propulsion systems, and avionics packaging. Create and maintain mechanical drawings, documentation, and product structures including BOMs and design trees. Support project planning and coordination, including subcontractor management where thermal subsystems or analyses are outsourced. Basic Qualifications (Required Skills & Experience)
Minimum 5+ years of relevant technical experience in thermal/mechanical engineering for UAVs, aerospace platforms, or advanced electronic systems. Proficiency in thermal modeling and simulation using ANSYS Icepak, ANSYS Mechanical, or equivalent FEA/CFD tools. Experience performing 3D FEA/CFD analyses for structural and thermal problems, including propulsion heating, fuselage insulation/blanketing, and avionics cooling. Strong knowledge of thermal management tradeoffs and materials properties, including adhesives, coatings, and insulating materials for extreme environments. Experience with heat sink design, airflow analysis, and environmental conditioning systems. Familiarity with environmental qualification requirements (DO-160, MIL-STD, or equivalent). Skilled in test and measurement techniques including thermal instrumentation, heat flux measurement, and environmental chamber testing. Proficiency in CAD tools (SolidWorks or equivalent) for mechanical modeling. Strong documentation skills, including requirements definition, BOM management, and technical risk assessment reporting. Qualifications
Experience applying RTCA DO-160, MIL-STD-810, or MIL-STD-1540 for environmental and thermal qualification of aerospace systems. Background in UAV/UAS thermal management, including propulsion heat rejection, fuselage insulation/blanketing, and avionics packaging strategies. Hands-on experience with thermal vacuum testing, altitude chambers, and propulsion thermal stress testing. Knowledge of fuel system thermal behavior and its impact on propulsion efficiency in UAV/UAS. Experience leading multidisciplinary design reviews with a focus on thermal performance and environmental survivability. Familiarity with model-based systems engineering (MBSE) tools such as Cameo for integrating thermal subsystem requirements into the overall UAV system design. Prior experience working with defense contractors, aerospace primes, or UAV/UAS OEMs on thermal or environmental subsystems. Salary Range: $140,000-170,000 The actual salary offered depends on location, candidate's knowledge, qualifications, skills, education, training, and experience. Note:
For remote/hybrid and/or California, Colorado, Maryland, Connecticut, Illinois, Minnesota, Vermont, Massachusetts, Nevada, New York, Rhode Island, Washington state, Cincinnati (OH), Jersey City (NJ), Toledo (OH) based roles, applicants must meet requirements. Compliance and Equal Opportunity
ALTEN Technology is an Equal Opportunity Employer. Our policy is to extend opportunities to qualified applicants and employees on an equal basis regardless of race, color, religion, sex, national origin, disability, veteran status, or other protected status. Important Notice
Job seekers should beware of scams. See our careers page for information about our recruiting process. Compliance Notice:
ALTEN USA is a federal contractor subject to VECRA and EO 11246. We are an Equal Opportunity Employer and consider all qualified applicants without regard to race, color, religion, sex, national origin, disability, veteran status, or other protected status. Drug Screening Requirement:
As a federal contractor, ALTEN USA maintains a drug-free workplace. All candidates selected for employment will be required to complete a pre-employment drug screening.
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