Southwest Research Institute (SwRI)

LEAD ENGINEER - PRINCIPAL ENGINEER - Avionics Thermal Design Engineer

Aerospace & Defense
11 - 15 years of experience
Job Overview by Ladders

Qualifications

  • Bachelor's degree in Mechanical Engineering, Thermal Engineering, Mechatronics Engineering, or a related field.
  • 11+ years of thermal engineering experience specifically in avionics with a focus on heat transfer and component derating.
  • Proficiency in advanced analysis tools (CFD/FEA) like Flotherm, Icepak, or ANSYS, including model correlation and sensitivity studies.
  • Strong ability to translate customer thermal requirements into actionable designs and lead the validation process.
  • Experience in collaborative systems integration, interfacing across disciplines such as electrical, mechanical, and systems engineering.

Responsibilities

  • Lead thermal architecture design for avionics under extreme conditions ensuring performance and reliability.
  • Deliver integratable thermal designs to minimize rework and schedule setbacks during integration and testing phases.
  • Conduct end-to-end compliance analysis and validation for customer and airworthiness requirements.
  • Drive modernization through strategic selection of components and thermal solutions enhancing maintainability and lifecycle costs.
  • Mentor engineering teams in thermal design standards, enhancing overall design readiness and production transition.
  • Perform thermal trade studies and resolve thermal management challenges collaboratively with cross-functional teams.
  • Plan and execute thermal verification tests, analyze results, and document compliance evidence for reviews.

Benefits

  • Opportunity for mentorship and professional development in a specialized engineering field.
  • Involvement in high-impact projects that contribute to national defense and aerospace innovation.
  • Access to advanced software tools and technologies for thermal analysis and design.
  • Collaborative work environment with multi-disciplinary teams enhancing systems integration capabilities.
  • Possibility of working on cutting-edge avionics solutions that have real-world applications.
Full Job Description
  • Lead thermal architecture for advanced avionics, ensuring electronics meet performance and reliability targets across worst-case mission environments (hot ramp, cold soak, high altitude).
  • Deliver flight-worthy, integratable thermal designs (conduction, convection, liquid/air cooling) that reduce risk, rework, and schedule impacts during integration and test.
  • Own end-to-end analysis and validation (CFD/FEA, derating, margins, qualification) to prove compliance with customer/airworthiness requirements and program commitments.
  • Drive DMSMS-aware modernization by selecting COTS/MIL-spec components and thermal solutions that improve sustainment, maintainability, and lifecycle cost.
  • Mentor teams and set technical standards for thermal design reviews, test readiness, and production transition, accelerating delivery of high-confidence avionics solutions.

  • Lead thermal trade studies for avionics (air/liquid cooling, conduction paths, materials), set margins, and resolve heat/airflow issues with electrical, mechanical, and systems teams.
  • Build/update CFD/FEA models, power maps, and derating analyses; document assumptions, sensitivities, and results to support rapid design decisions and integration readiness.
  • Support lab bring-up and troubleshooting-instrumentation, data review, root-cause of hot spots, and corrective actions for hardware and packaging changes.
  • Plan/execute thermal verification (TVAC/temperature rise, airflow tests), define test procedures, analyze results, and produce compliance evidence for reviews and airworthiness artifacts.
  • Drive design reviews and configuration control-approve drawings/BOM impacts, coordinate suppliers, and mentor engineers on thermal standards, best practices, and lessons learned.

  • Requires a Bachelors degree in Mechanical Engineering, Thermal Engineering, Mechatronics Engineering or related engineering degree with directly related experience.
  • 11+ years: Expert thermal engineering for avionics: heat transfer, thermal networks, component derating, and margining across flight and ground extremes; strong fundamentals plus practical packaging insight.
  • 11+ years: Advanced analysis skills: CFD/FEA (e.g., Flotherm/Icepak/ANSYS), model correlation, uncertainty/sensitivity studies, and turning results into clear design decisions and requirements.
  • 11+ years: Requirements-to-results driver: translate customer thermal/performance requirements into actionable design constraints, lead trades to meet SwRI design standards, and deliver verified thermal margin with clear compliance evidence.
  • 11+ years: Systems integration skills: partner across EE/ME/SE, manage interfaces and configuration, drive technical reviews, mentor engineers, and communicate effectively with customers and program leadership.
  • A valid/clear driver's license is required.

About Southwest Research Institute (SwRI)

Southwest Research Institute (SwRI) is a non-profit research and development organization headquartered in San Antonio, Texas. The institute was founded in 1947 and has since grown to employ over 3,000 people across multiple locations in the United States. SwRI provides research and development services to a variety of industries, including automotive, aerospace, and energy. The institute's research areas include automation and data systems, chemistry and chemical engineering, and space science and engineering. SwRI has a long history of working with government agencies, including NASA and the Department of Defense, as well as private companies.
Learn more about Southwest Research Institute (SwRI)
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