This is a rare chance to work at the intersection of advanced simulation, AI, and real-world hardware - solving genuinely hard thermal problems with a high degree of ownership and technical freedom. You'll be joining a small, high-calibre team where your work directly shapes both the product and the company's trajectory.
About the Role
We're partnered with a seed-stage, venture-backed engineering company building next-generation thermal hardware using advanced simulation and AI-driven design tools.
They are looking for a Senior Thermal Engineer with deep expertise in heat transfer and fluid dynamics - not a generalist, but someone who specialises in thermal systems and enjoys solving complex heat exchanger problems from first principles.
This is a high-impact, individual contributor role where you'll act as both a designer and technical authority - owning designs from concept through to manufacturable hardware, while working closely with cutting-edge software tools to push performance beyond traditional limits.
What You'll Be Doing
- Design heat exchangers end-to-end - from blank CAD through to simulation-backed, production-ready geometry
- Use CFD and 1D modelling to evaluate performance, optimise designs, and guide engineering decisions
- Validate and challenge outputs from advanced design tools, ensuring physical accuracy and real-world viability
- Balance thermal performance with pressure drop, manufacturability, and system constraints
- Design for additive manufacturing, accounting for build constraints, distortion, and post-processing
- Plan and interpret experimental validation, closing the loop between simulation and physical testing
- Develop reusable models, tools, and frameworks to accelerate future design cycles
Experience
- PhD in Mechanical Engineering, Aerospace Engineering, or related field
- ~5+ years of post-PhD experience in thermal engineering
- Proven experience designing heat exchangers or similar thermal systems
Technical Skills
- Strong background in heat transfer, fluid dynamics, and conjugate heat transfer
- Hands-on experience with CFD tools (e.g. STAR-CCM+, Ansys Fluent, OpenFOAM)
- Experience with 1D modelling tools (e.g. EES or similar)
- CAD experience (e.g. NX, SolidWorks) with production intent
- Familiarity with additive manufacturing constraints (particularly metal AM)
What Sets You Apart
- Deep passion for thermal systems and first-principles engineering
- Ability to move from theory → simulation → real hardware
- Strong intuition for physical correctness beyond just simulation outputs
- Experience working in fast-paced or early-stage environments
Additional Details
- Fully remote within the US (preference for East Coast hours)
- Competitive base salary + meaningful early-stage equity
- No visa sponsorship available
