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 related field with relevant experience.
  • 11+ years of expertise in thermal engineering for avionics, covering heat transfer, thermal networks, component derating, and margining.
  • Advanced skills in CFD/FEA tools (e.g., Flotherm, Icepak, ANSYS) with a strong focus on model correlation and design validation.
  • Proven ability to convert customer thermal and performance requirements into actionable design constraints.
  • Extensive experience in systems integration, managing technical interfaces, and mentoring engineers across disciplines.

Responsibilities

  • Lead thermal architecture design for avionics to ensure reliability under extreme conditions.
  • Deliver flight-worthy thermal designs that minimize risks and streamline integration processes.
  • Conduct end-to-end analysis and validation using CFD/FEA to meet safety and performance standards.
  • Implement modernization strategies through selection of COTS/MIL-spec components that enhance lifecycle cost and maintainability.
  • Mentor engineering teams and establish technical standards for thermal reviews and production transitions.
  • Perform thermal trade studies and build/update models for informed decision-making.
  • Plan and execute thermal verification tests, analyze outcomes, and document compliance evidence.

Benefits

  • Engagement in cutting-edge technology and innovation in avionics.
  • Mentorship opportunities to enhance career growth and development.
  • Collaborative work environment with cross-functional teams.
  • Involvement in high-stakes projects with direct impact on mission success.
  • Access to professional development and continuous learning resources.
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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