Principal Thermal Design Engineer/Thermal Lead (R3050)

About Shield AI     

Founded in 2015, Shield AI is a venture-backed defense technology company focused on protecting service members and civilians with intelligent systems. Its flagship autonomy software, Hivemind, powers aircraft, drones, and other platforms, enabling complex missions with high reliability in contested environments. With offices in San Diego, Dallas, Washington, D.C., and internationally, Shield AI’s products actively support U.S. and allied operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn,Twitter, and Instagram.   

Job Description:

Are you a passionate and innovative Thermal Engineering Lead looking to develop state-of-the-art AI and robotics products? Are you eager to make a meaningful impact? Do you thrive in a mission-driven, values-focused environment? Shield AI is the place for you!

As a Thermal Engineering Lead, you will drive the thermal architecture, analysis, and design of our autonomous UAV products, ensuring they operate reliably under extreme conditions. You’ll take ownership of complex thermal challenges, leveraging first-principles engineering, prototyping, testing, and optimization to push the boundaries of current technology. Working closely with cross-functional teams, you’ll play a pivotal role in integrating thermal solutions from early concept through production, ensuring best-in-class performance and reliability.

This role requires a deep technical understanding of thermal systems, a hands-on approach to problem-solving, and the ability to guide teams in implementing best practices throughout the product lifecycle. If you’re looking for a high-impact role where you can shape the thermal design of next-generation autonomous systems, we’d love to hear from you!

• Own and drive the thermal architecture, design, and analysis for aircraft and ground systems.
• Solve complex thermal challenges using first-principles engineering and innovative approaches.
• Optimize cooling solutions for performance, reliability, and manufacturability.
• Develop FEA models (FLOEFD, ANSYS, Icepak, Flotherm) to predict and validate thermal performance.
• Guide system architecture decisions with thermal considerations at the forefront.
• Lead thermal verification testing, sensor selection, data acquisition, and post-processing.
• Conduct failure reviews, root-cause analyses, and implement design improvements.
• Drive best practices and standardization in thermal modeling, design, and test methodologies.
• Act as a technical mentor, providing guidance on thermal best practices and design reviews.
• Proactively identify and implement innovative solutions that improve system performance and V-BAT reliability.
• Collaborate with internal teams and external partners to ensure seamless integration of thermal solutions.
• Other duties as assigned.

• B.S. or M.S. in Thermal/Mechanical Engineering or equivalent.
• Extensive experience in thermal design and analysis, with a proven track record of excellence.
• Deep understanding of heat transfer, fluid dynamics, and thermodynamics.
• Expertise in FEA tools (FLOEFD, ANSYS, Icepak, Flotherm).
• Hands-on testing experience – sensor selection, data acquisition, and data post-processing.
• 3D modeling expertise in Siemens NX or equivalent.
• Strong analytical skills with the ability to make data-driven design decisions.
• A demonstrated record of working hard, being a trustworthy teammate, and upholding high standards.
• Proven ability to take ownership of complex problems and drive them to resolution.
• Experience shipping products, successfully navigating development cycles, and delivering high-quality solutions under tight timelines.

• Experience designing cutting-edge autonomous robotic systems.
• Background in fast-paced environments, startups, or R&D settings.
• Proven ability to adapt, innovate, and execute under pressure.

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Total package details for U.S. based positions:

- Regular employee positions: Salary within range listed above + Bonus + Benefits + Equity

- Temporary employee positions: Hourly within range listed above + temporary benefits package (applicable after 60 days

of employment)

- Interns/Military Fellows/Part-time not eligible for bonus, benefits or equity

Total package details for International positions which are roles based outside of the United States (where applicable):

- International premium, hardship differential, cost of living differential, living quarters allowance, foreign service transfer

allowance, equity, international benefits, visa assistance, and relocation assistance.

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.

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.