Sr Staff Engineer, HVAC + Thermal Systems
aptera motorsCarlsbad (CA)
Sr Staff Engineer, HVAC + Thermal Systems
Posted 2 days ago
aptera motorsCarlsbad (CA)
Mechanical EngineersAir-Conditioning and Warm Air Heating Equipment and Commercial and Industrial Refrigeration Equipment Manufacturing
SENIORITY
Lead
About the role
Senior Staff Engineer, HVAC & Thermal Systems Aptera Motors is dedicated to building a future where every journey is powered by the sun. We specialize in creating solar electric vehicles that revolutionize the way we travel, providing sustainable and efficient transportation solutions. Carlsbad, California | Engineering | Full-time
About the role:
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.
What you'll do:
- 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)
Qualifications:
- 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
Preferred Qualifications:
- Experience with solar-integrated or ultra-high-efficiency vehicle platforms
- Experience designing HVAC systems specifically optimized for range extension in EVsProficient 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
- Team Structure
- Individual contributor; collaborate with other teams and individuals, as necessary
Required Experience:
- 15+ years of relevant experience in automotive HVAC, thermal systems, or thermal management engineering
- Educational Requirements
- Bachelor's degree in Mechanical Engineering, Thermal Engineering, or a related field; Master's degree preferred
- Salary + Benefits
- Market competitive compensation package
- Stock option grants
- Fully funded benefits package for employee + dependents
- Generous Flexible Time Away policy
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