Sr. Principal Mechanical Engineer (Thermal Analysis SME)

Job Description
BAE Systems is seeking a Principal Mechanical Engineer to serve as a Subject Matter Expert (SME) in thermal analysis and management. This role is critical in designing and validating innovative thermal solutions to ensure the reliability and performance of dynamic electronic military systems operating in extreme environments.
The ideal candidate will possess a deep expertise in heat transfer, thermodynamics, and thermal modeling, with a proven track record of driving thermal strategies from the IRAD/Proposal phase through to the Qualification phase.
Key Responsibilities
Technical Leadership & Thermal Oversight: Provide lead thermal oversight for entire projects, complex modules, or high-power LRUs/boxes, operating with high autonomy to ensure thermal stability and system reliability.
Thermal Analysis Authority: Hold primary responsibility and authority for all thermal design and analysis. Utilize advanced simulation tools to predict thermal behavior and solve complex heat dissipation challenges.
Business Pursuit & Customer Engagement: Support key business pursuits by defining thermal requirements and constraints that meet customer needs; serve as the primary technical point of contact for thermal architecture during customer engagements.
Thermal Solution Development: Develop and optimize robust thermal management solutions (e.g., conduction cooling, liquid cooling, advanced heat sinks) to meet demanding environmental specifications.
SME Analysis & Review: Act as the Thermal Engineering SME and reviewer; perform high-level complex thermal analyses and present findings effectively to program leadership and customers.
Project Integration: Collaborate across disciplines (Electrical, Mechanical, and Systems) to ensure that thermal constraints are integrated into the overall design, and that cost, schedule, and technical risks are addressed.
Business Initiative Driver: Promote and implement strategic initiatives related to thermal modeling standards, simulation automation, and rigorous peer review processes for thermal reports.
Team Mentorship: Lead and mentor a team of engineers, guiding them in the application of thermal analysis best practices to advance their technical proficiency.
Detailed Execution: Generate and assess thermal models, perform steady-state and transient analyses, and define test plans for thermal verification and qualification.
Required Education, Experience, & Skills
Experience: 6+ years of experience in mechanical engineering, with a specialized focus on thermal analysis and a demonstrated ability to lead thermal strategies through the full lifecycle (IRAD/Proposal to Qual Phase).
Technical Expertise: Expert-level background in heat transfer and thermodynamics with the ability to operate as a lead analyst and SME reviewer.
Communication: Excellent leadership and communication skills, with the confidence to interface directly with customers regarding complex technical trade-offs.
Operational Ability: Proven ability to work individually or in small team environments and execute complex thermal projects with little to no programmatic support.
Industry Knowledge: Experience working with integrated military electronic hardware, high-power density electronics, and related thermal test equipment.
Security Clearance: Must be able to obtain a Secret Clearance
Preferred Education, Experience, & Skills
Soft Skills

• Excellent leadership and communication skills
• Strong written and verbal communication skills
• Ability to work individually and in team environments
• Strong problem-solving skills and ability to execute complex projects
• Motivated self-starter and problem solver with proven experience executing in multi-disciplinary teams

Pay Information
Full-Time Salary Range: $132962 - $226035
Please note: This range is based on our market pay structures. However, individual salaries are determined by a variety of factors including, but not limited to: business considerations, local market conditions, and internal equity, as well as candidate qualifications, such as skills, education, and experience.
Employee Benefits: At BAE Systems, we support our employees in all aspects of their life, including their health and financial well-being. Regular employees scheduled to work 20+ hours per week are offered: health, dental, and vision insurance; health savings accounts; a 401(k) savings plan; disability coverage; and life and accident insurance. We also have an employee assistance program, a legal plan, and other perks including discounts on things like home, auto, and pet insurance. Our leave programs include paid time off, paid holidays, as well as other types of leave, including paid parental, military, bereavement, and any applicable federal and state sick leave. Employees may participate in the company recognition program to receive monetary or non-monetary recognition awards. Other incentives may be available based on position level and/or job specifics.
About BAE Systems Electronic Systems
BAE Systems, Inc. is a defense, aerospace, and security company headquartered in Falls Church, Virginia, with more than 40,000 employees worldwide. We serve, supply, and protect those who protect us. As one of the most geographically diverse international defense companies, we deliver a full range of products and services spanning air, land, maritime, space, and cyber, including advanced electronics, intelligence solutions, and dedicated customer support.
Our culture is performance-driven and values-led, built on curiosity, creativity, and collaboration. Purpose isn't a tagline here. It's what drives us. We're developing breakthrough technologies that defend national security and make a lasting impact on our communities and our planet. When you join BAE Systems, you're not just building a career. You're contributing to a mission that truly matters.
This position will be posted for at least 5 calendar days. The posting will remain active until the position is filled, or a qualified pool of candidates is identified.