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Senior Thermal Systems Engineer

2 months ago


Santa Ana, California, United States Overair, Inc. Full time
Job Overview

Company Overview:

Overair, Inc. is at the forefront of sustainable air transport innovation, committed to making next-generation electric vertical takeoff and landing (eVTOL) aircraft accessible to everyone. Our flagship product, Butterfly, represents a groundbreaking all-electric VTOL aircraft aimed at transforming urban mobility. With a rich history of over twenty years in VTOL aircraft development, patented technologies, and extensive flight vehicle expertise, Overair is dedicated to addressing the challenges of sustainable air mobility.

Position Summary:

We are seeking a skilled Senior Thermal Engineer to contribute to the evolution of Butterfly as the leading eVTOL in the Urban Air Mobility (UAM) sector. The selected candidate will be part of the Propulsion Engineering team, tasked with the design, planning, and execution of research and development for both current and future products.

This role is hands-on and demands both technical expertise and innovative problem-solving abilities. Ideal candidates will excel in designing, planning, and developing testing processes while also supporting ground and flight tests.

The successful candidate will thrive in a dynamic environment and possess a strong understanding of the design, development, and testing lifecycle associated with rapid aerospace research and development. Collaboration and meticulous attention to detail are essential, as this role involves close interaction with engineers across various teams and program management, necessitating excellent communication and interpersonal skills.

Key Responsibilities:

  • Lead the design, analysis, and enhancement of thermal systems for eVTOL aircraft.
  • Work collaboratively with interdisciplinary teams to ensure effective thermal management of essential components, including batteries, motors, power electronics, and propulsion systems.
  • Conduct thermal simulations and analyses to forecast and optimize temperature distributions, heat transfer, and thermal stresses.
  • Execute thermal testing and validation of components and systems to confirm performance under real-world conditions.
  • Collaborate closely with electrical, mechanical, and aerodynamics engineers to seamlessly integrate thermal solutions into the overall aircraft design.
  • Engage with suppliers and vendors to procure thermal management components and technologies.
  • Participate in design reviews, offering thermal expertise and recommendations to ensure compliance with performance requirements.
  • Document thermal design processes, simulations, and test outcomes for future reference and knowledge sharing.
  • Support project management activities by coordinating thermal engineering efforts, monitoring progress, and adhering to project timelines.

Required Qualifications:

  • Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related discipline; a Master's or Ph.D. in Thermal Engineering or a relevant field is preferred.
  • 5-7 years of professional experience in thermal engineering within the aerospace or aviation sectors.
  • Demonstrated experience in designing and analyzing thermal systems for complex engineering projects, ideally involving electric aircraft or aerospace systems.
  • Proficiency with thermal simulation tools such as ANSYS Fluent, COMSOL, or similar software for modeling heat transfer, fluid dynamics, and temperature distributions.
  • Strong understanding of thermal analysis and heat transfer principles, including conduction, convection, and radiation.
  • Familiarity with thermal management technologies, including cooling solutions, heat exchangers, thermal insulation, and phase change materials.
  • Knowledge of thermal regulations and standards applicable to aerospace applications.
  • Ability to utilize CAD software (e.g., SolidWorks or CATIA) for collaborative thermal design integration.
  • Excellent problem-solving skills to effectively address thermal challenges.
  • Capacity to work within cross-functional teams and collaborate with engineers from diverse disciplines.

Preferred Qualifications:

  • Experience with eVTOL aircraft projects or electric propulsion systems.
  • Understanding of battery thermal management systems, motors, and propulsion systems and their integration in aerospace applications.
  • Familiarity with FAA 14 CFR Part 91 regulations.
  • Experience with FAA airworthiness certifications and requirements (Part 23 and/or Part 27).
  • Knowledge of problem reporting and task tracking systems (e.g., JIRA).
  • Experience with requirements capture and tracking software (e.g., JAMA).

Benefits Overview:

  • Comprehensive medical, dental, and vision coverage for employees and their dependents.
  • Flexible Spending Account with a company match of up to $1,000.
  • 401(k) plan featuring a 6% company match, with no vesting period and immediate eligibility.
  • 12 weeks of supplemental paid family leave.
  • Company-sponsored Life & AD&D Insurance.
  • Optional Life, Accident, Hospital Indemnity, and Critical Illness insurance.
  • Employee equity incentive program (stock options).
  • No-cost Employee Assistance Program and Virtual Counseling.
  • Generous paid time off policy, including 4 weeks of vacation, 10 holidays, 6 sick days, and volunteer time.

Diversity and Inclusion Commitment:

At Overair, we believe that diversity and inclusion are essential to our success. By embracing diverse ideas and approaches, we enhance our ability to deliver optimal results for our employees, environment, and business partners. We cultivate a culture where all colleagues can share their passions and ideas, enabling us to collectively tackle industry challenges and work towards a brighter future.

Overair is an Equal Opportunity / Affirmative Action Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, veteran status, age, or any other federally protected class.