The Thermal/Stress Engineer performs integrated thermal and structural analyses of aerospace components and systems operating in extreme flight environments. This role involves developing detailed finite element models, analyzing thermal and mechanical behavior under a variety of load conditions, and supporting design decisions through simulation and test correlation. The engineer collaborates cross-functionally with design, systems, materials, and test teams to ensure compliance with mission and regulatory requirements.
Key Responsibilities:
Develop and execute thermal and structural analysis plans for aircraft and spacecraft structures, including launch vehicles, satellites, and re-entry systems
Build, validate, and refine finite element models (FEM) for structural stress, thermal conduction/radiation, and coupled load analysis
Evaluate performance under dynamic, static, and thermal loads (e.g., ascent heating, cryogenic exposure, re-entry heat flux, and launch loads)
Analyze complex boundary conditions and material behaviors, including composites, metallics, and thermal protection systems
Correlate analysis results with test data from thermal-vacuum testing, load testing, and vibration environments
Participate in design reviews, trade studies, and risk assessments related to thermal and stress performance
Support the definition of test requirements and assist in post-test evaluations and failure investigations
Generate formal analysis reports, interface documentation, and technical presentations for internal and customer reviews
Interface with systems engineers, design teams, and suppliers to guide design optimization and integration strategies
Key Focus Areas:
Finite Element Analysis (FEA) for thermal and stress conditions
Coupled load analysis and test correlation
Structural and thermal margin assessments under aerospace environmental conditions
Engineering support from concept to verification
Qualifications & Skills:
Education:
Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or related discipline (required)
Master’s degree preferred
Experience:
3–7 years of experience performing thermal and structural analyses in aerospace or related industries
Direct involvement in development or flight programs with exposure to extreme temperature or load environments
Technical Skills:
Proficiency in thermal and FEA tools (e.g., ANSYS, Thermal Desktop, NASTRAN, Abaqus, FEMAP)
Working knowledge of CAD platforms for interfacing with design models (e.g., Creo, CATIA, SolidWorks)
Strong understanding of heat transfer, structural mechanics, and materials behavior in aerospace applications
Familiarity with environmental test methods, standards, and correlation techniques
Soft Skills:
Strong problem-solving skills and engineering judgment
Effective communication skills with the ability to present complex data clearly
Self-starter with the ability to manage multiple tasks in a deadline-driven environment
Team-oriented with a collaborative mindset