Sr. Aerothermal Development Engineer

Rivian•Irvine, CA

About The Position

The Sr. Aerothermal Development Engineer supports the Thermal Attributes process from initial target setting to final vehicle level sign off. A high focus on benchmarking and customer fleet analysis is part of supporting the Attribute target definition. DVP creation, test planning, vehicle preparation as well as data analysis are part of the daily activities for this role. Support chamber and road trip testing for HVAC and Propulsion Conditioning Attributes as well and hardware/software development. Manage opening and closure of engineering concerns and issues throughout the vehicle life.

Requirements

Bachelor’s or Graduate Degree in Engineering (Mechanical/Aerospace) from an accredited University with a strong background in Thermodynamics, Heat Transfer, Fluid Mechanics, and Experimental Methods/Data Analysis.
2-5 years’ experience in automotive thermal system development, HVAC design, or electronics cooling, with a demonstrated strong emphasis on physical testing and data analysis.
Expertise in thermal instrumentation, data acquisition, and advanced post-processing techniques for large datasets.
Proven experience analyzing complex thermal and HVAC performance data to identify trends, diagnose issues, and drive solutions.
Strong understanding of control systems and experience proposing/supporting control logic changes for thermal management systems.
Working knowledge of automotive communication protocols (CAN, LIN, Ethernet) and relevant debugging tools.
A proven track record of data-driven problem-solving and independent root cause analysis.
Excellent communication, interpersonal, and teamwork skills, with the ability to clearly present complex technical information to diverse audiences.
The proven ability to produce clean, organized, and timely documentation.
Ability to work autonomously and lead individual efforts while performing as part of a cross-functional team.

Nice To Haves

Detailed understanding and experience with automotive refrigerant / heat pump systems is preferred.
Knowledge of electric vehicle HVAC and Heating / Cooling systems is a strong plus.
Background in calibration for HVAC and Propulsion Conditioning is a strong plus.
Foundational understanding of aerothermal simulation principles (CFD, thermal comfort) and ability to interpret simulation results for correlation and diagnostic purposes.

Responsibilities

Lead the planning and execution of thermal system development and validation testing, including travel to off-site locations for testing in extreme hot and cold conditions.
Develop comprehensive test procedures that align with user stories and attribute requirements, ensuring high-quality and actionable test results.
Specify, plan, and assist with vehicle instrumentation, ensuring data acquisition solutions meet required accuracy and robustness.
Identify, document, and proactively address system design gaps and vehicle issues throughout all phases of testing and development based on empirical data.
Support chamber and on road testing for HVAC and Propulsion Conditioning Attributes, contributing to both hardware and software development.
Create and maintain detailed testing documentation, including test plans, verification procedures, and comprehensive test reports detailing analysis findings during development cycle and sign off procedure.
Drive the development and refinement of control strategies for HVAC and thermal management systems based directly on test data analysis and identified performance gaps.
Collaborate closely with HVAC control strategy lead & controls engineers to propose and implement logic changes that optimize thermal comfort, energy efficiency, and system response.
Perform in-depth data analysis of complex test data from vehicle, subsystem, and component-level aerothermal tests (e.g., thermal comfort, system capacity, HVAC/propulsion conditioning performance).
Present compelling analysis results to leadership and cross-functional teams, highlighting key findings, root causes, and recommended solutions.
Utilize a foundational understanding of aerothermal simulation (CFD, thermal comfort) to correlate simulation results with physical data, and assist in diagnosing complex issues identified during testing.
Participate in cross-functional teams (Studio, Thermal, Interior, Exterior, Controls) to develop and implement innovative and efficient HVAC and cooling strategies, with a strong emphasis on data-driven decisions.
Manage opening and closure of engineering concerns and issues throughout the vehicle life, ensuring robust root cause analysis using test data.