Staff Mechanical Engineer – Thermal Simulation & Analysis

The Role
Apptronik is seeking a Staff Mechanical Engineer – Thermal Simulation & Analysis to lead the thermal architecture of our humanoid robot, Apollo. In a humanoid system, high-power
actuators, high-performance compute clusters, and dense battery packs are packed into tight, mobile volumes—creating one of the most challenging thermal environments in robotics.
As a Staff Engineer, you are the technical authority for the entire "thermal stack". You will move beyond simple steady-state analysis to model complex, transient thermal events during high-intensity robot maneuvers. You will influence the robot's physical architecture from the concept phase, ensuring that we maximize performance and duty cycle without compromising safety or hardware longevity.

Key Responsibilities
● Thermal Architecture Leadership: Own the thermal roadmap for the humanoid platform. Define the cooling strategies (passive, active, or phase-change) for high-torque actuators and high-density compute enclosures.
● High-Fidelity Simulation: Develop complex CFD (Computational Fluid Dynamics) and heat transfer models using industry-standard tools (e.g., Ansys Icepak/Fluent, Simscale, or).
● Transient Duty Cycle Modeling: Predict thermal behavior during dynamic robot activities (walking, lifting..) where power consumption varies rapidly, necessitating complex transient thermal-fluid analysis.
● Multi-Physics Integration: Work closely with Structural Simulation engineers to perform Fluid-Structure Interaction (FSI) and thermal-stress analysis on critical components like motor housings and battery frames.
● Test & Correlation: Design and lead physical thermal validation experiments. Utilize IR thermography, thermocouples, and flow sensors to correlate real-world data with your simulation models.
● DfX & Manufacturing Support: Collaborate with the DfX team to select specialized materials (TIMs, heat spreaders, high-conductivity alloys) that balance thermal performance with weight and cost.
● Mentorship: Act as the subject matter expert (SME) for thermal issues company-wide, mentoring junior engineers and establishing standardized thermal design rules.

Qualifications
● Experience: 8+ years of experience in thermal design and simulation for high-performance electromechanical systems (Robotics, EV, Aerospace, or High-End Computing).
● Simulation Mastery: Expert-level proficiency in CFD software and a deep understanding of conduction, convection (natural and forced), and radiation in complex assemblies.
● Hardware Depth: Proven track record of designing and shipping hardware with challenging thermal constraints; experience with embedded compute thermal management or high-flux motor cooling is a significant plus.
● Analytical Skills: Ability to perform "back-of-the-envelope" thermal calculations to guide design decisions before full CFD results are available.
● Education: BS/MS in Mechanical Engineering (PhD preferred) with a focus on Heat Transfer or Fluid Dynamics.

PHYSICAL REQUIREMENTS
● Prolonged periods of sitting at a desk and working on a computer
● Must be able to lift 15 pounds at times
● Vision to read printed materials and a computer screen
● Hearing and speech to communicate