(Fastwater Staffing) SENIOR THERMAL ENGINEER

Location & Work Arrangement

• Costa Mesa, CA (On-site) preferred
• Remote opportunities may be considered for exceptionally strong candidates located elsewhere in the U.S.

Employment Details

• Contract: 6 months, with potential for extension or conversion to a permanent position
• Target Bill Rate: Up to $120/hour

Requirements

• Must be a U.S. Citizen
• Must be eligible to obtain and maintain a Top Secret security clearance

What You'll Do

· Own thermal design and analysis for integrated hardware products, including drones, aircraft, missiles, or related defense systems.

· Use first-principles engineering judgment to determine the right level of analysis for each design decision, including hand calculations, spreadsheets, MATLAB / Python models, FEA, and CFD.

· Define thermal architectures that can withstand rugged environments, demanding flight envelopes, and operational edge cases, including hot, cold, transient, and mission-specific thermal conditions.

· Partner with electrical, mechanical, aerospace, software, and systems engineers to document power dissipation, operating modes, thermal constraints, and design tradeoffs.

· Build and maintain thermal FEA / CFD models to predict system performance, establish design limits, and define red / yellow operating thresholds for test and field use.

· Define and execute prototype builds and thermal tests, including CAD support, sensor selection, DAQ setup, data post-processing, and results documentation.

· Present thermal status, risks, tradeoffs, timelines, and recommendations in internal design reviews and customer-facing technical reviews.

· Develop internal tools, workflows, or analysis methods that improve speed, consistency, and quality of thermal decision-making.

· Support failure reviews and root-cause investigations using test data, thermal analysis, and first-principles reasoning.

Required Qualifications

· MS or PhD in Mechanical Engineering, Aerospace Engineering, Applied Physics, or a related field with a focus on heat transfer, fluid dynamics, thermal sciences, or thermal systems.

· 5+ years of experience designing, analyzing, or validating thermal systems for integrated hardware products.

· Strong first-principles understanding of heat transfer and fluid dynamics, including conduction, convection, radiation, fluid flow, and transient thermal behavior.

· Experience supporting thermal design for aerospace, aircraft, rocket, missile, UAV, defense, or other high-performance hardware systems.

· Experience using thermal analysis, modeling, simulation, and/or physical test data to drive design decisions for passive or active thermal management systems.

· Ability to communicate technical tradeoffs clearly across engineering, program, and customer stakeholders, and ability to obtain and maintain a U.S. Top Secret security clearance.

Preferred Qualifications

· Experience with thermal analysis tools such as STAR-CCM+, ANSYS, Icepak, Flotherm, or comparable FEA / CFD platforms.

· Experience using MATLAB, Python, spreadsheets, or similar tools for first-order thermal modeling, transient analysis, or engineering trade studies.

· Experience designing thermal hardware such as heat sinks, cold plates, fans, pumps, heat exchangers, thermal interface materials, liquid cooling systems, or air-cooling systems.

· Experience planning or executing thermal tests, including sensor selection, data acquisition, data post-processing, and correlation of test results to analysis.

· Experience with SolidWorks, Siemens NX, or comparable CAD tools.

· Experience supporting formal design reviews, customer reviews, flight test, qualification testing, or fielded hardware.

· Experience developing reusable analysis tools, automation workflows, reduced-order models, or other methods that improve analysis speed and consistency.

· Strong motivation to support Client's mission of defending the United States and allied partners.