Senior Mechanical Engineer – Thermal Simulation & Analysis

ESSENTIAL DUTIES AND RESPONSIBILITIES

• Design and develop thermal management solutions (passive and active) for actuators, compute systems, and battery packs
• Build and execute CFD and heat transfer simulations to guide design decisions
• Perform transient thermal analysis for dynamic robot operation and varying duty cycles
• Collaborate cross-functionally with mechanical, electrical, and controls teams to integrate thermal solutions
• Supports test plan creation by identifying critical thermal scenarios from CFD and transient models and defining corresponding instrumentation and test procedures
• Mentor junior level engineers and act as the technical escalation point for hardest problems
• Correlate simulation results with physical test data and refine models accordingly
• Contribute to material selection (TIMs, heat spreaders, alloys) balancing performance, weight, and cost
• Develop and document thermal design guidelines and best practices

Skills And Requirements

• Strong proficiency in CFD tools (e.g., Ansys Icepak, Fluent, or similar)
• Solid understanding of heat transfer principles: conduction, convection, and radiation
• Experience with transient thermal modeling and real-world duty cycles
• Ability to perform first-order thermal calculations to guide design decisions
• Strong cross-functional collaboration and communication skills
• Experience working with physical hardware and test environments

Education And/or Experience

• Bachelor’s or Master’s degree (or equivalent) in Mechanical Engineering or related field
• At least 5–8 years of experience in thermal design and simulation for electromechanical systems

Physical Requirements

• Prolonged periods of sitting at a desk and working on a computer
• Must be able to lift 15 pounds at times
• Vision to read printed materials and a computer screen
• Hearing and speech to communicate