Senior HVAC Systems Design Engineer (Military & Rugged Applications)

Role Overview

We are seeking a high-caliber Senior HVAC Systems Design Engineer to spearhead the development of mission-critical, ultra-rugged environmental control systems. In this role, you will bridge the gap between advanced thermal science and rugged mechanical design, engineering specialized air conditioning solutions built to survive the world’s harshest environments. You will own the product lifecycle from initial thermodynamic modeling and 3D CAD layout to live prototype testing and military-standard validation.

• Reports To: Engineering Director / Systems Engineering Manager
• Direct Reports: None initially; provides technical mentorship to junior engineers and technicians.
• Location/Format: On-site (Requires hands-on lab validation)

(Sponsorship is not available for this role.)

Key Responsibilities

System Design & Component Selection

• Design complete, high-performance air conditioning systems from the ground up.
• Select and optimize critical thermal components, including heat exchangers, compressors, and fans.
• Lead transition strategies to low-GWP refrigerants compliant with evolving DoD regulations.
• Execute precise airflow designs, static pressure calculations, and fan curve matching.
• Maximize system Coefficient of Performance (COP) utilizing specialized AC design software and advanced Excel/macro models.

Electrical & Control Systems

• Architect electrical control systems, including safety timers, switch selection, and power distribution layout.
• Program rugged system controllers utilizing Ladder Logic and Structured Text.
• Engineering electrical power budgets optimized for generator-based grids, implementing strategies to strictly minimize inrush currents.
• Develop detailed electrical and plumbing schematics using AutoCAD.

Mechanical, Structural & Simulation Design

• Create robust 3D part and assembly designs using SolidWorks or Creo, with a heavy emphasis on rugged sheet metal enclosures.
• Generate production-ready Bills of Materials (BOMs), assembly drawings, and fabrication blueprints.
• Conduct targeted Computational Fluid Dynamics (CFD) simulations to analyze internal airflow and eliminate thermal hot spots.

Environmental, Durability & Mission Integration

• Ruggedize systems to withstand extreme shock, vibration, blowing sand, dust, and torrential rain.
• Design against strict military benchmarks, specifically MIL-STD-810 (Environmental) and MIL-STD-461 (EMI/EMC).
• Select advanced materials to guarantee corrosion resistance, lightweight structural integrity, and fault-tolerant operation in poorly maintained field environments.
• Balance competing constraints: deliver ultra-compact, lightweight layouts that minimize noise signatures while maintaining full operational redundancy.

Prototyping, Testing & Validation

• Build, wire, and instrument physical prototypes for hands-on experimental testing.
• Validate thermal performance inside environmental chambers under non-standard, extreme ambient conditions.
• Conduct acoustic testing and implement specialized noise-damping treatments.
• Perform Failure Mode and Effects Analysis (FMEA) to guarantee mission-critical reliability.

Qualifications & Skills

Education & Experience

• Degree: Bachelor of Science in Mechanical Engineering (BSME) or equivalent from an ABET-accredited institution. A Master’s degree is a plus.
• Licensure: Professional Engineer (PE) registration is highly desirable.
• Experience: 3 to 5+ years of dedicated experience in HVAC, refrigeration, or thermal management systems design.
• Must be a US Citizen due to ITAR.

Technical & Core Competencies

• Software Mastery: Proficiency in SolidWorks/Creo, AutoCAD, and HVAC system simulation software. Advanced Excel (VBA/macros) skills.
• Regulatory Knowledge: Deep understanding of thermodynamics, fluid mechanics, and low-GWP refrigerant alternatives.
• Operational Excellence: Strong working knowledge of Lean Manufacturing, Six Sigma methodologies, and continuous improvement tools.