Mechanical Engineer - Thermal Analysis, Amazon Prime Air, Drone Delivery
Confirmed on the employer's own hiring board on Oct 19, 2026. First seen by Alion on Oct 13, 2026. Amazon scores B on the Alion truth index.
Hardware Development Engineer II - Thermal Analysis
We are seeking a Hardware Development Engineer II to join our Electric Propulsion Subsystem team. In this role, you will be a significant and autonomous contributor, solving difficult thermal engineering problems for an electric aerial drone. You will own the thermal analysis and thermal management strategy for the vehicle's battery pack, electric motors, power electronics, and avionics, developing high-fidelity FEA and CFD models that drive design decisions.
This position requires an engineer who demonstrates strong technical depth in heat transfer, fluid dynamics, and numerical simulation while also exhibiting the system-level thinking and influence characteristic of our most impactful contributors.
Key job responsibilities
- Develop high-fidelity FEA and CFD thermal models of the drone's battery pack, motors, power electronics, and avionics, capturing conduction, convection, and radiation across the full flight envelope and ambient operating range.
- Define and develop thermal management strategies and systems for the battery pack, including cold-weather heating, in-flight and ground cooling, and cell-to-cell temperature uniformity.
- Develop cooling strategies for electric motors and motor controllers, including forced-air and conductive paths, and trade thermal performance against mass, drag, and packaging constraints.
- Analyze candidate designs and quantify thermal margins, hot-spot locations, transient temperature response, and sensitivity to operating conditions, and communicate results as clear design recommendations.
- Perform thermal analysis of avionics systems, defining heat-sinking, airflow, and conduction paths that maintain component junction temperatures within reliability limits.
- Build reduced-order and lumped-parameter thermal models derived from high-fidelity simulations for use in system-level performance, range, and mission-planning tools.
- Define and execute thermal test campaigns, including instrumented bench tests, environmental chamber tests, and flight test data collection, and correlate physical results to analysis models.
- Establish thermal design requirements and operating limits.
Basic qualifications
- 4+ years of working in mechanical engineering or equivalent experience
- Bachelor's degree in mechanical engineering or equivalent
- Experience developing and validating thermal models including reduced-order models, FEA, and CFD.
Preferred qualifications
- Master's degree in mechanical engineering or equivalent
- Experience with electric powertrain components and thermal management systems design
- Experience with applicable aerospace design standards including DO-25, DO-160G, SAE AIR1168, or MIL-STD-810
Amazon is an equal opportunity employer and does not discriminate on the basis of protected veteran status, disability, or other legally protected status.
Our inclusive culture empowers Amazonians to deliver the best results for our customers. If you have a disability and need a workplace accommodation or adjustment during the application and hiring process, including support for the interview or onboarding process, please visit https://amazon.jobs/content/en/how-we-hire/accommodations for more information. If the country/region you’re applying in isn’t listed, please contact your Recruiting Partner.
The base salary range for this position is listed below. Your Amazon package will include sign-on payments and restricted stock units (RSUs). Final compensation will be determined based on factors including experience, qualifications, and location. Amazon also offers comprehensive benefits including health insurance (medical, dental, vision, prescription, Basic Life & AD&D insurance and option for Supplemental life plans, EAP, Mental Health Support, Medical Advice Line, Flexible Spending Accounts, Adoption and Surrogacy Reimbursement coverage), 401(k) matching, paid time off, and parental leave. Learn more about our benefits at https://amazon.jobs/en/benefits.
USA, WA, Seattle - 117,300.00 - 160,000.00 USD annually