Sr. Mechanical

Dorleco is seeking a highly skilled Sr. Mechanical & Thermal Systems Engineer to lead the design, analysis, and validation of advanced battery and power distribution systems for next-generation electric and autonomous platforms. This role involves developing mechanical and thermal requirements, building high-fidelity system models, optimizing thermal architectures, and driving design decisions through simulation and testing. You will support prototype builds, ensure production readiness, and maintain compliance with global safety standards.

The ideal candidate brings deep expertise in thermal management, mechanical design, FEA/CFD, and model-based development, along with strong collaboration across engineering, manufacturing, and supply chain teams.

• Mount View , CA

Systems Engineering, Requirements and Architecture Development:

• Write and manage thermal performance and safety requirements for battery packs and power distribution components.
• Write and manage Mechanical performance and safety requirements for battery packs and power distribution components.
• Use full-system models, simulations, and test results to derive and validate requirements and system architecture
• Ensure thermal requirements integrate seamlessly into the broader system architecture and operational conditions.
• Sustaining ownership of battery components already entering production, interfacing with manufacturing team to make drawing and design updates as necessary
• Participate inPerforming detailed tolerance stack-ups, FEA simulations, and DFMEA to validate designs
• Support high-voltage safety design practices, including creepage/clearance considerations, shielding, and sealing for HV components
• Develop and release 2D drawings and 3D CAD models using NX
• Manage and support prototype builds and validation testing, incorporating feedback into iterative design cycles
• Interface with manufacturing and supply chain partners to ensure design intent is maintained through production

System Modeling & Simulation:

• Develop full thermal system models using tools like Simscape to simulate interactions between components under varying operational scenarios.
• Perform detailed thermal analyses with 3D modeling tools (e.g., ANSYS, Fluent, COMSOL) to evaluate heat transfer, fluid dynamics, and system performance.
• Use simulation results to drive design decisions and refine requirements.

Thermal System Design & Optimization:

• Design and optimize thermal management solutions for battery cells, modules, and power distribution components, including cooling, heating, and insulation strategies.
• Ensure that thermal systems are integrated effectively with mechanical, electrical, and energy storage subsystems.

Prototyping, Testing & Validation:

• Lead the planning and execution of thermal testing to validate models and ensure compliance with requirements.
• Analyze experimental data to enhance system models and inform
• iterative design improvements. Use experimental data to create model validation reports which quantify model fidelityand error

Safety & Compliance:

• Develop Mechanical and thermal management strategies to mitigate risks such as overheating and thermal runaway.
• Ensure systems meet relevant aviation and battery safety standards (e.g., RTCA DO-160G, DO-311, UN 38.3, SAE J2464).

Technology Development & Continuous Improvement:

• Stay at the forefront of thermal management technologies and system modeling tools to drive innovation.
• Contribute to the development of a technology roadmap for thermal systems within the battery team.

• Bachelor's or Master's degree in Mechanical or Thermal Engineering, Aerospace Engineering, or a related field.
• 5+ years of experience in thermal systems engineering, including systems modeling and requirements development.
• Proficiency with system modeling tools such as Simscape or similar platforms.
• Experience with 3D thermal analysis tools (e.g., ANSYS, Fluent, COMSOL).
• Experience with 3D CAD tools (e.g., NX, SolidWorks, Catia)
• Proven ability to write, analyze, and manage requirements based on simulation and testing.
• Strong understanding of heat transfer, thermodynamics, and fluid dynamics principles.
• Hands-on experience with thermal prototyping and testing.
• Familiarity with aviation or battery safety standards ARP4754, DO-160G, DO-311.

• Experience with systems engineering in aerospace, aviation, or electric vehicle industries.
• Familiarity with eVTOL operational environments and requirements.
• Knowledge of advanced cooling and thermal insulation technologies.
• Expertise in battery thermal runaway prevention and mitigation.
• Strong analytical skills and experience with MATLAB/Simulink environments