The Senior Thermal/Stress Engineer provides technical leadership in the analysis, design, and validation of aerospace structures and systems subjected to extreme thermal and mechanical environments. This role is responsible for developing advanced thermal-structural models, executing coupled simulations, driving design optimization, and mentoring junior engineers. The engineer interfaces across disciplines to ensure high-reliability aerospace hardware meets mission-critical requirements from concept through flight certification.
Key Responsibilities:
Lead thermal and structural analysis efforts for complex aerospace systems including launch vehicles, space platforms, re-entry vehicles, and high-speed aircraft
Develop high-fidelity finite element models to simulate steady-state, transient, and coupled thermo-mechanical conditions
Evaluate structural integrity and thermal performance under static loads, dynamic environments (shock, vibration, acoustic), and thermal extremes (cryogenic to hypersonic)
Own margin of safety calculations, load path assessments, and thermal protection system (TPS) analysis
Correlate simulation results with test data (e.g., thermal-vacuum, static load, modal, thermal cycle) and adjust models accordingly
Provide technical leadership in design reviews, interface control, and failure investigations
Collaborate with materials, systems, test, and design engineering to guide selection of materials, joints, fasteners, and insulation methods
Define and review test requirements, instrumentation strategies, and post-test analysis plans
Generate formal engineering documentation, including analysis reports, compliance matrices, and presentation packages for internal and customer-facing reviews
Mentor junior engineers, establish best practices, and support continuous improvement of simulation and verification methodologies
Key Focus Areas:
Advanced thermal and structural simulation using FEA and heat transfer modeling
Multiphysics and coupled analysis in high-performance aerospace environments
Technical leadership in design validation and test correlation
Cross-functional collaboration on thermal/stress-driven design decisions
Qualifications & Skills:
Education:
Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or related field (required)
Master’s or PhD preferred in relevant disciplines
Experience:
8–15+ years of experience in aerospace thermal and structural analysis
Track record of supporting spaceflight or high-performance aircraft programs through full development lifecycle
Experience working with flight hardware, environmental qualification, and certification processes
Technical Skills:
Expert-level proficiency with FEA and thermal tools (e.g., ANSYS Mechanical, Thermal Desktop, SINDA/FLUINT, NASTRAN, Abaqus, FEMAP)
Strong grasp of heat transfer mechanisms, stress-strain behavior, materials science, and failure modes in aerospace contexts
Deep knowledge of aerospace standards, analysis methodologies, and structural margin verification practices
Familiarity with CAD and PLM systems, and test data analysis tools (MATLAB, Python, etc.)
Soft Skills:
Strong leadership, communication, and mentoring skills
Ability to translate complex analysis results into actionable design insights
Detail-oriented with high standards of quality and accountability
Strategic thinker with strong problem-solving and decision-making abilities