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About the Role

Orbital is seeking a highly skilled and innovative Thermal Engineer to develop next-generation cooling technologies for high-density data center applications. The role spans the full development cycle: from modeling and simulations to cold plate design, condenser optimization, physical prototyping, flow loop construction, and system-level testing. You will work directly with novel refrigerators and proprietary AI toolsets to push the boundaries of speed and efficiency in data center cooling.

Responsibilities

Design, build and operate two-phase test loops, analyse performance data and rapidly iterate towards solutions that can scale from prototype to product.
Evaluate candidate refrigerants based on thermodynamic properties, saturation temperature, safety classification, material compatibility, and regulatory requirements for integration into two-phase cooling designs.
Design and optimize evaporator cold plates including channel geometry selection, inlet restriction sizing and exit vapor quality targeting.
Evaluate and develop enhanced boiling surfaces to improve nucleation site density and increase critical heat flux margins.
Construct thermal test vehicles to evaluate cold plate performance under control and representative heat flux conditions.
Operate two-phase test loops to characterize flow, generate boiling curves and CHF data.
Translate experimental findings into design rules and validated simulation inputs.
Perform system-level thermodynamic analyses: pressure-enthalpy cycle mapping, charge optimization, subcooling control, and component sizing for two-phase flow.
Use or direct CFD or other modeling tools to evaluate cold plate designs, flow distribution in manifolds and thermal stresses in assemblies.
Build or contribute to system-level models for cycle analysis, parametric studies and impact of fluid properties on total performance.
Support Obrital’s proprietary fluid development efforts by contributing to compatibility testing, accelerated aging studies, and performance characterization.
Specify materials, bonding processes, and manufacturing methods for prototype and production cold plate units.
Responsible for the direction of intermediate engineers, designers, and researchers contributing to two-phase development.
Produce technical reports, test plans, and design specifications for internal and external stakeholders.

Requirements

Degree in mechanical engineering, chemical engineering or a closely related discipline with 5+ years of experience.
Demonstrated experience in single or two-phase heat transfer, boiling phenomena or refrigeration system design.
Proficiency in conducting thermodynamic analysis to optimize cooling system performance, energy efficiency and heat transfer.
Hands-on prototyping and lab experience: ability to design test fixtures, build flow loops, select and install instrumentation, and run experiments independently.
Experience with or strong aptitude for CAD for test fixture design.
Ability to interpret experimental data and translate findings into design improvements.
Continuous improvement mindset.
Background in chemistry, materials science, or chemical engineering as it relates to refrigerant behavior, surface treatments,or coating processes is a strong plus.
Experience with relevant simulation software (e.g. CFD, FEA) for thermal and fluid dynamics an asset.
Familiarity or experience with cold plate manufacturing processes (CNC machining, brazing, sintering, skiving) is an asset.

Skills

Thermal Engineer
Cooling technologies
High-density data center applications
Modeling
Simulations
Cold plate design
Condenser optimization
Physical prototyping
Flow loop construction
System-level testing
Refrigerators
AI toolsets
Two-phase test loops
Thermodynamic properties
Saturation temperature
Safety classification
Material compatibility
Regulatory requirements
Channel geometry selection
Inlet restriction sizing
Exit vapor quality targeting
Enhanced boiling surfaces
Nucleation site density
Critical heat flux margins
Thermal test vehicles
Heat flux conditions
Flow characterization
Boiling curves
CHF data
Design rules
Validated simulation inputs
System-level thermodynamic analyses
Pressure-enthalpy cycle mapping
Charge optimization
Subcooling control
Component sizing
Two-phase flow
CFD
FEA
Cold plate designs
Flow distribution in manifolds
Thermal stresses in assemblies
System-level models
Cycle analysis
Parametric studies
Fluid properties
Proprietary fluid development
Compatibility testing
Accelerated aging studies
Performance characterization
Materials specification
Bonding processes
Manufacturing methods
Prototype and production cold plate units
Direction of intermediate engineers
Technical reports
Test plans
Design specifications
Single or two-phase heat transfer
Boiling phenomena
Refrigeration system design
Thermodynamic analysis
Cooling system performance
Energy efficiency
Heat transfer
Prototyping
Lab experience
Test fixture design
Flow loops
Instrumentation selection and installation
Experiment execution
CAD
Experimental data interpretation
Design improvements
Continuous improvement
Chemistry
Materials science
Chemical engineering
Refrigerant behavior
Surface treatments
Coating processes
Simulation software
Thermal and fluid dynamics
Cold plate manufacturing processes
CNC machining
Brazing
Sintering
Skiving

Experience Level

5+ years of experience

Education Level

Degree in mechanical engineering, chemical engineering or a closely related discipline

Benefits

Competitive salary and equity package
Flexible and generous paid time off
Excellent health, dental and vision insurance plan
Regular company offsites

About the Company

Orbital is an AI-first industrial company building hardware from the atoms up.
Our goal is to lead an industrial renaissance to advance critical technologies and secure our planet for generations to come.
We’re starting with critical hardware for AI data centers to make them more performant and sustainable.
Every Orbital product is invented with our AI platform — uniting AI-automated hardware engineering with AI-designed material science to achieve breakthrough real-world performance.
We have an ambitious mission and need excellent people in all our teams - AI research, operations, advanced materials, mechanical engineering, chemical engineering and manufacturing.
Working at Orbital means working in tightly integrated, vertically integrated teams.
We’re looking for people who have a love of physical technology, curiosity in AI and a desire to learn.
The experience of working in a cutting-edge organisation dedicated to a better future.

Equal Opportunity

Orbital is an equal opportunity employer.
We celebrate diversity and are committed to creating an inclusive environment for all employees.