Sr. Principal Mechanical Engineer (Thermal Analysis SME)

Key Responsibilities

• Provide lead thermal oversight for entire projects, complex modules, or high-power LRUs/boxes, operating with high autonomy to ensure thermal stability and system reliability.
• Hold primary responsibility and authority for all thermal design and analysis. Utilize advanced simulation tools to predict thermal behavior and solve complex heat dissipation challenges.
• Serve as the primary technical point of contact for thermal architecture during customer engagements.
• Develop and optimize robust thermal management solutions (e.g., conduction cooling, liquid cooling, advanced heat sinks) to meet demanding environmental specifications.
• Act as the Thermal Engineering SME and reviewer; perform high-level complex thermal analyses and present findings effectively to program leadership and customers.
• Collaborate across disciplines (Electrical, Mechanical, and Systems) to ensure that thermal constraints are integrated into the overall design, and that cost, schedule, and technical risks are addressed.
• Promote and implement strategic initiatives related to thermal modeling standards, simulation automation, and rigorous peer review processes for thermal reports.
• Lead and mentor a team of engineers, guiding them in the application of thermal analysis best practices to advance their technical proficiency.
• Generate and assess thermal models, perform steady-state and transient analyses, and define test plans for thermal verification and qualification.

Required Education, Experience, & Skills

• 6+ years of experience in mechanical engineering, with a specialized focus on thermal analysis and a demonstrated ability to lead thermal strategies through the full lifecycle (IRAD/Proposal to Qual Phase).
• Expert-level background in heat transfer and thermodynamics with the ability to operate as a lead analyst and SME reviewer.
• Excellent leadership and communication skills, with the confidence to interface directly with customers regarding complex technical trade-offs.
• Proven ability to work individually or in small team environments and execute complex thermal projects with little to no programmatic support.
• Experience working with integrated military electronic hardware, high-power density electronics, and related thermal test equipment.

Soft Skills

• Strong written and verbal communication skills.
• Ability to work individually and in team environments.
• Strong problem-solving skills and ability to execute complex projects.
• Motivated self-starter and problem solver with proven experience executing in multi-disciplinary teams.

About BAE Systems

BAE Systems, Inc. is the U.S. subsidiary of BAE Systems plc, an international defense, aerospace and security company which delivers a full range of products and services for air, land and naval forces, as well as advanced electronics, security, information technology solutions and customer support services. Improving the future and protecting lives is an ambitious mission, but it’s what we do at BAE Systems. Working here means using your passion and ingenuity where it counts – defending national security with breakthrough technology, superior products, and intelligence solutions. As you develop the latest technology and defend national security, you will continually hone your skills on a team—making a big impact on a global scale.

Electronic Systems

Electronic Systems (ES) is the global innovator behind BAE Systems’ game-changing defense and commercial electronics. Exploiting every electron, we push the limits of what is possible, giving our customers the edge and our employees opportunities to change the world. Our products and capabilities can be found everywhere – from the depths of the ocean to the far reaches of space. At our core are more than 14,000 highly talented Electronic Systems employees with the brightest minds in the industry, we make an impact – for our customers and the communities we serve.