Lead Thermal Design Engineer

About the role

You will own the full lifecycle design of solar thermal receivers, translating high-level system requirements into detailed thermal and structural architectures. You will spearhead the development of novel receiver geometries and materials that maximize energy capture while ensuring longevity under extreme conditions. You will lead cross-functional collaboration, aligning optical modeling, thermal analysis, and manufacturing constraints to deliver robust hardware solutions. You will drive experimental validation, using test data to refine models and accelerate design iterations toward performance targets. You will establish and maintain rigorous engineering standards for thermal performance, safety, and reliability across the product line. You will mentor junior engineers, fostering a culture of technical excellence, curiosity, and clear communication within the thermal systems team. You will interface directly with key stakeholders to integrate feedback, manage trade studies, and keep project timelines on track. You will champion cost-conscious innovation, identifying opportunities to simplify designs and reduce bill of materials without compromising quality or durability.

Key facts

What you'll do

Define the thermal and structural architecture of solar receivers, specifying materials, coatings, and geometries to handle high-flux solar radiation.

Develop analytical and computational models for heat transfer, fluid flow, and thermal stress to predict receiver performance and guide design decisions.

Lead the design of receiver components, including absorber surfaces, support structures, and thermal interfaces, to optimize efficiency and durability.

Establish test protocols and validation procedures, correlating simulation results with experimental data to refine models and improve accuracy.

Collaborate with optical engineers to ensure receiver designs align with solar concentration characteristics and spectral response requirements.

Partner with manufacturing teams to translate prototypes into scalable production designs, addressing fabrication tolerances and assembly methods.

Drive failure mode analysis and reliability assessments, implementing design improvements to mitigate risks and extend component lifetimes.

Support system integration by defining thermal storage interfaces, heat extraction strategies, and operational envelopes for real-world conditions.

Evaluate emerging materials and coating technologies, assessing their suitability for high-temperature, high-irradiance environments.

Own documentation deliverables, including design specifications, analysis reports, and test records that meet regulatory and quality standards.

Coordinate with project management to track milestones, manage trade-offs, and ensure deliverables meet schedule and performance goals.

Lead root cause investigations for performance deviations, using field and lab data to guide corrective actions and prevent recurrence.

Mentor and guide junior thermal engineers, providing technical direction, review, and hands-on support for complex design challenges.

Champion best practices in thermal engineering, promoting traceability, rigor, and continuous improvement across the product development lifecycle.

Requirements

Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a closely related technical field required; Master's or PhD preferred.

Demonstrated experience in thermal design, heat transfer analysis, and computational fluid dynamics relevant to high-temperature systems.

Proven background in handling high-flux solar energy, concentrated solar power, or similar high-heat flux applications.

Strong knowledge of materials engineering, including material selection, thermal expansion, creep, and degradation mechanisms at elevated temperatures.

Experience with optical-thermal coupling, surface coatings, and radiative properties relevant to solar energy absorption and retention.

Proficiency in engineering analysis tools such as finite element analysis, system energy modeling, and performance simulation software.

Excellent problem-solving skills, with the ability to translate ambiguous requirements into concrete engineering tasks and test plans.

Strong communication skills, capable of presenting complex technical concepts to both technical and non-technical stakeholders.

Self-motivated with a disciplined approach to documentation, traceability, and design governance in a fast-paced environment.

Willingness to travel as needed for testing, validation, and collaboration with external partners or facilities.

Nice to have

Experience with additive manufacturing techniques for thermal components or advanced fabrication methods.

Familiarity with system-level modeling of energy storage and power conversion in renewable energy applications.

Background in concentrated solar power receiver development or high-temperature thermochemical energy storage.

Prior work in a startup or high-growth environment where rapid prototyping and iterative design are essential.

Knowledge of regulatory and certification considerations for energy infrastructure equipment.

Practical notes

Relocation to Miami, FL or Austin, TX is required for this role.

Exowatt provides relocation assistance to support your move.