Mechanical Thermal Analysis Engineer

We’re ALTEN Technology USA, an engineering company that provides solutions for engineering, technology, and product development projects. For decades, we’ve been helping our clients develop products that are changing the world, whether that’s by shaping the future of space exploration, saving lives with medical devices that set a new standard of care, or creating the fully autonomous electric taxi of tomorrow. Our team of more than 600 people works across industries including aerospace, medical devices and life sciences, unmanned systems and robotics, automotive OEM and tier 1 suppliers, commercial vehicle, electric vehicles, rail, and more. Our offices across the US have different industry focuses and engage with our clients in different ways, ranging from working on-site at client facilities to performing product development at our delivery centers.
 
ALTEN Group, our parent company, has been a leader in engineering and information technology for more than 30 years. ALTEN Group operates in 30 countries across Europe, North America, Asia, Africa and the Middle East and employs more than 36,000 people, 88% of whom are engineers. The company covers the whole development cycle and offers a choice of service levels, from technology consulting to complete project outsourcing.
 
When you join ALTEN Technology USA, you join a group of people passionate about collaborating to solve some of the world’s most technical engineering challenges. Our success is tied to taking care of our employees by building relationships and providing opportunities for mentorship and career growth. We offer comprehensive benefits for all full-time employees, including medical, dental, and vision insurance; a 401(k) plan with employer matching; paid time off (PTO); paid parental leave; and mentorship to help you take your career to the next level. You don’t have to take our word for it that we are a great place to work—we were named on the 2023 Top Workplaces list thanks to feedback from our proud employees.

The Mechanical Thermal Analysis Engineer applies advanced thermal and mechanical engineering techniques to design, analyze, and validate UAV/UAS platforms operating in demanding terrestrial and high-altitude environments. This role focuses on developing and implementing thermal management solutions for propulsion systems, avionics, and fuselage structures, ensuring reliability under stringent environmental conditions. The engineer will assess technical risks associated with testing high-flying systems, lead detailed thermal analyses, and create predictive models to support safe and efficient system performance.

Position Responsibilities

• Lead or support thermal analysis efforts for UAV/UAS systems, including propulsion heating effects, 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 system performance.

• Support environmental requirements definition and compliance (thermal, vibration, altitude, and humidity conditions).

• 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.

Preferred Qualifications

• Experience applying RTCA DO-160, MIL-STD-810, or MIL-STD-1540 for environmental and thermal qualification of aerospace systems.

• Direct 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 systems.

• 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 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 is dependent on various factors including, but not limited to, location, the candidate’s combination of job-related knowledge, qualifications, skills, education, training, and experience 

MANDATORY FOR ALL REMOTE/HYBRID AND/OR CALIFORNIA, COLORADO, MARYLAND, CONNECTICUT, ILLINOIS, MINNESOTA, VERMONT, MASSACHUSETTS, NEVADA, NEW YORK, RHODE ISLAND, WASHINGTON STATE & CINCINNATI, OHIO, JERSEY CITY, NEW JERSEY, TOLEDO, OHIO BASED ROLES. 

Note: Due to the nature of the work, only US Persons (citizens or permanent residents) need apply for this position.

ALTEN Technology is an Equal Opportunity Employer. Our Policy is to extend opportunities to qualified applicants and employees on an equal basis regardless of an individual’s age, race, color, sex, religion, national origin, disability, sexual orientation, gender identity/expression or veteran status.

Please beware of job seeker scams and see this important notice on our careers page for more information about our recruiting process.

Compliance Notice: Alten USA is a federal contractor subject to the requirements of the Vietnam Era Veterans’ Readjustment Assistance Act (VEVRAA) and Executive Order 11246. We are an Equal Opportunity Employer and consider all qualified applicants without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or veteran status.

Drug Screening Requirement: As a federal contractor, Alten USA maintains a drug-free workplace. All candidates selected for employment will be required to successfully complete a pre-employment drug screening as a condition of hire.