Staff Thermal Engineer

CHAOS Industries is redefining modern defense with a multi-product portfolio that gives the ultimate advantagedomain dominance. The companys products are powered by Coherent Distributed Networks (CDN) empowering warfighters commercial air operators and border protection teams to act faster adapt rapidly and stay ahead of evolving threats.

CHAOS Industries was founded in 2022 and has raised a total of $1 billion in funding from leading investors including 8VC Accel and Valor Equity Partners. The company is headquartered in Los Angeles with offices in Washington D.C. San Francisco San Diego and London. For more information please visit.

Role Overview:

CHAOS is seeking a Staff Thermal Engineer to perform thermal and fluid-flow analysis of electronic components circuit card assemblies (CCAs) and electronic enclosures. The role spans design trades detailed analysis hardware integration qualification and production support.

You will analyze heat transfer and internal fluid flow including air and liquid coolants in cabinets coldplates and heat exchangers. You will work closely with electrical and mechanical designers providing technical guidance to improve thermal performance and resolve design challenges. You will plan and support tests perform data reduction and correlate thermal models with test results.

• This is a full-time on-site position in El Segundo CA.
• This requisition is open to candidates who may be considered for a lower or higher job level. Final level and grade will be determined based on relevant experience skills and qualifications.

Responsibilities:

• Perform hand calculations and detailed thermal analyses of electronic components CCAs and enclosures
• Develop and use ANSYS Icepak models for electronics cooling and internal air and liquid coolant flow
• Analyze cooling systems that include cabinets coldplates heat exchangers and related hardware
• Assess temperatures flow distribution pressure drop and thermal margins across expected operating conditions
• Define model inputs assumptions and boundary conditions and communicate their effect on results
• Provide practical thermal design guidance to electrical and mechanical designers
• Identify thermal risks and recommend design changes in collaboration with multidisciplinary teams
• Participate in design and peer reviews
• Plan and support thermal tests analyze test data and correlate models with test results
• Support board and system bring-up qualification troubleshooting and production issues
• Document analysis methods assumptions results and recommendations

Minimum Requirements:

• Bachelors degree in Mechanical Engineering or a related STEM field and 7 years of relevant experience
• Hands-on experience performing electronics thermal analysis using ANSYS Icepak
• Strong working knowledge of heat transfer thermodynamics and fluid mechanics
• Experience analyzing thermal performance of electronic components circuit boards or enclosures
• Ability to perform engineering hand calculations and assess when detailed simulation is needed
• Experience analyzing liquid-cooled coldplates and heat exchangers
• Experience with forced-air cooling flow distribution pressure-drop analysis and fan performance
• Strong technical communication skills and ability to work independently across engineering disciplines
• Ability to obtain and maintain a U.S. security clearance

Preferred Requirements:

• Masters degree in Mechanical Engineering or a related field
• Experience with Macroflow STAR-CCM NX thermal or other thermal or CFD software
• Experience planning or supporting thermal tests reducing test data or correlating analysis models
• Experience with aerospace defense or other high-reliability electronic systems
• Familiarity with MIL-STD-810 RTCA/DO-160 or VITA-48

Why CHAOS

• Health Benefits: Medical dental and vision benefits 100% paid for by the company
• Additional benefits: 401k ( 50% company match up to 6% of pay) FSA HSA life insurance and more
• Our Perks: Free daily lunch while youre working onsite fully-stocked kitchen unlimited PTO casual dress code
• Compensation Components: Competitive base salaries generous pre-IPO stock option grants relocation assistance and (coming soon!) annual bonuses
• Team Growth: 500employees and counting across 5 global offices

The stated compensation range reflects only the targeted base compensation range and excludes additional earnings such as bonus equity and benefits. If your compensation requirements fall outside of the range we still encourage you to apply. The salary range for this role is an estimate based on a range of compensation factors inclusive of base salary only. Actual salary offer may vary based on (but not limited to) work experience education and/or training critical skills and/or business considerations.

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