Sr Staff Engineer, HVAC + Thermal Systems

Aptera Motors•Carlsbad, CA

10d

About The Position

Aptera is seeking a Senior Staff Engineer, HVAC & Thermal Systems to lead thermal architecture and HVAC system development for our solar electric vehicle. In this role, you'll define and execute the thermal strategy that keeps our vehicle's occupants comfortable and its battery, powertrain, and electronics running efficiently, all while protecting the ultra-low energy consumption that makes Aptera's solar vehicle possible.

Requirements

15+ years of relevant experience in automotive HVAC, thermal systems, or thermal management engineering
Deep expertise in vehicle HVAC systems and thermal architecture, including battery thermal management systems for electric vehicles
Proven track record leading thermal system design from concept through production launch
Strong background in CFD and thermal simulation tools
Hands-on experience with climate chamber and physical thermal validation testing
Experience with HVAC systems and its major components and technologies
Strong cross-functional collaboration skills, working closely with battery, powertrain, and body engineering teams
Demonstrated technical leadership and mentorship of engineering teams
Excellent communication skills, with the ability to translate complex thermal engineering concepts for cross-functional stakeholders

Nice To Haves

Experience with solar-integrated or ultra-high-efficiency vehicle platforms
Experience designing HVAC systems specifically optimized for range extension in EVs
Proficient with CATIA V6 or similar automotive CAD/simulation tools
Experience working in a startup or fast-paced product development environment
Patents, publications, or conference contributions in automotive thermal management

Responsibilities

Lead the design, development, and vehicle validation of HVAC and thermal management systems for Aptera's solar vehicle platform, including battery thermal management (all systems), cabin climate control, and power electronics cooling
Define thermal architecture strategy that balances energy efficiency, range, and occupant comfort, a critical trade-off given the vehicle's ultra-aerodynamic, solar-charging design
Own thermal system requirements, specifications, and performance targets from concept through production
Lead HVAC calculations and simulation work (CFD, 1D/3D modeling) to predict, validate, and optimize system performance ahead of physical testing
Plan and lead HVAC system validation and thermal programs, including climate chamber testing, hot/cold weather development, and real-world performance verification
Partner cross-functionally with battery, powertrain, body, and electrical teams to integrate thermal systems into the overall vehicle architecture
Select and manage relationships with HVAC and thermal component suppliers, including compressors, heat exchangers, refrigerant systems, and heat pumps
Provide technical leadership and mentorship to junior and mid-level HVAC and/or thermal engineers
Drive root-cause analysis and resolution of thermal-related field and test issues
Ensure HVAC system designs comply with relevant automotive thermal and refrigerant safety standards
Maintain accurate HVAC and thermal systems documentation within the vehicle's Build of Materials (BOM)