Thermal Design Engineer

About the role

Bamboohr is seeking a Thermal Design Engineer to join their team based in Wayne, Pennsylvania. This full-time position focuses on developing and optimizing thermal management solutions for electronic systems and components. The engineer will work on analyzing heat transfer, designing cooling systems, and ensuring products meet thermal performance targets. The role involves collaboration with cross-functional teams to integrate thermal considerations into the product development lifecycle from early concept through production.

Key facts

What you'll do

Lead thermal analysis projects using computational fluid dynamics and finite element methods to model heat flow in electronic assemblies. Design and evaluate heat sinks, fans, heat pipes, and other cooling components for optimal thermal performance. Create detailed thermal models and simulations to predict temperature distributions across printed circuit boards and enclosures. Collaborate with mechanical and electrical engineers to develop thermal solutions that fit within product form factor constraints. Conduct physical thermal testing in laboratory environments to validate simulation predictions and identify design improvements. Document thermal design decisions, analysis results, and test findings in engineering reports and technical specifications. Review vendor thermal data and component datasheets to ensure selected parts meet system-level thermal requirements. Support design for manufacturing by evaluating thermal performance trade-offs and cost considerations during the design phase. Participate in design reviews and provide thermal expertise to identify and resolve overheating issues early in development. Maintain and update thermal design guidelines and best practices for the engineering organization to follow across projects.

Requirements

Bachelor's degree in mechanical engineering, aerospace engineering, or a closely related technical discipline is required. A minimum of three years of professional experience in thermal design or thermal analysis for electronics is expected. Proficiency in at least one major thermal simulation platform such as ANSYS Icepak, Flotherm, or COMSOL Multiphysics is necessary. Strong understanding of heat transfer fundamentals including conduction, convection, and radiation principles is essential. Experience with computational fluid dynamics tools and the ability to interpret complex simulation results is required. Familiarity with printed circuit board layout and electronic component packaging thermal characteristics is needed. Excellent written and verbal communication skills for presenting findings to both technical and non-technical stakeholders. Ability to manage multiple projects simultaneously and meet established deadlines in a fast-paced engineering environment.

Nice to have

Experience with thermal interface materials selection and application in real-world electronic assemblies is valued. Prior work with high-power density electronics such as power converters or processors is a plus. Knowledge of industry standards and reliability testing methods for thermal validation is beneficial. Familiarity with Python or MATLAB for automating thermal analysis workflows and post-processing simulation data is welcomed.

Skills & tools

Computational fluid dynamics simulation software such as ANSYS Fluent or Star-CCM+ for detailed flow and thermal modeling. Finite element analysis tools including ANSYS Mechanical or Abaqus for structural thermal and conjugate heat transfer studies. Electronic cooling design expertise covering heat sinks, forced air cooling, liquid cooling loops, and phase change materials. Thermal testing equipment including thermocouples, infrared cameras, and environmental chambers for physical validation of designs. CAD software such as SolidWorks or Creo for creating thermal component geometries and integrating them into assemblies. Data analysis and visualization tools for interpreting test results and presenting thermal performance trends clearly.

Practical notes

This role is based at the Wayne, Pennsylvania office and requires on-site presence during regular business hours. The hiring process includes a technical interview covering thermal analysis fundamentals and a design exercise. Bamboohr offers a competitive benefits package and opportunities for professional development in thermal engineering. Candidates should be prepared to discuss previous thermal design projects and the specific tools they have used during the interview process.