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Aurelius Systems is a VC-backed defense tech startup building autonomous, edge-deployed directed energy systems (laser weapons) for counter-UAS applications. The company operates from San Francisco with a manufacturing hub in Detroit and conducts weekly field tests on a private 400-acre range.
You will own the complete thermal architecture of Archimedes, the company's flagship laser weapon system, with primary focus on the turret and gimbal subsystems housing the laser source. This is a thermal leadership role where you set the design philosophy and build the simulation framework for a high-power directed energy system that must operate reliably in real-world outdoor environments.
Key responsibilities include: designing and implementing cooling loops with pumps, heat exchangers, cold plates, and working fluid selection; performing thermal simulation in ANSYS, COMSOL, or equivalent tools; modeling thermal behavior across the optical chain, motor drives, power electronics, and ambient conditions; optimizing heat sink design and conduction paths for high-power-density components; developing and executing thermal qualification tests including cycling and steady-state characterization; partnering with optics teams on thermal lensing and beam quality; and selecting materials for thermal performance across metals, ceramics, and composites.
Required qualifications: 5–10+ years in mechanical engineering with primary focus on thermal design and implementation; proven hands-on experience specifying pumps, sizing heat exchangers, selecting working fluids, and building systems that meet thermal targets; direct experience implementing cooling solutions for high-power systems; strong simulation background in ANSYS Thermal, COMSOL, or equivalent with required CFD experience; deep understanding of conduction, convection, radiation, and two-phase cooling; hands-on test and validation experience with thermal cycling, IR imaging, thermocouple instrumentation, and steady-state characterization; expert-level CAD proficiency (SolidWorks, Creo, or similar); BS or MS in Mechanical Engineering, Aerospace Engineering, or related field.
Nice-to-haves include familiarity with turret, gimbal, or rotating-joint hardware; active security clearance or ability to obtain one; and knowledge of MIL-STD-810 and MIL-STD-461 qualification standards.
The role operates with core hours Monday–Friday, 9 AM–6 PM, with intensity ramping during sprints toward demos or field tests. The company emphasizes extreme bias for action, rapid prototyping, and self-directed work within a small ~10-person engineering team with minimal hierarchy. This role requires U.S. Person status due to export control requirements.
