Senior Thermal Analyst

LEAP; Broomfield (CO); Hybrid; USD 135,000 - 165,000; Full time

Benefits offered by this job

Equity Program

401(k) plan

Professional development stipend

Flexible PTO

Hybrid work model

Health benefits

Life and disability insurance

Job summary

LEAP is seeking a Senior Thermal Analysis Engineer in Colorado to advance rocket technologies from concept to production. You will perform hand calculations, FEA, and testing to ensure mechanical and thermal designs meet strict performance and manufacturability goals.

You will own thermal protection sizing, analyze loads and gradients, and collaborate with design, avionics, and fabrication teams to drive programs to flight. Strong communication and independent work are essential.

Qualifications

• Bachelor's degree in Mechanical or Aerospace engineering from an accredited university.
• 6–10 years of Aerospace analysis experience.
• Proficiency with NX, FEMAP, Nastran, ABAQUS, Fluent, TMG or Thermal Desktop.

Responsibilities

• Identify and solve technical challenges with speed.
• Own sizing of thermal protection systems for all components.
• Calculate loads, heat flux and gradients for the analysis team.
• Ensure thermal margins meet mission needs.
• Develop test plans for Thermal/TVAC/Wind Tunnel and document data.
• Support qualification testing and correlate models with results.
• Produce and iterate designs using structural, thermal, and/or fluids analysis for flight vehicles.

Skills

Thermal analysis

FEA/CAE

CAD/CAE

Instrumentation selection

Thermal product sizing

Independent work

Communication

Documentation

Education

Mechanical or Aerospace engineering degree

Tools

NX

FEMAP

Nastran

ABAQUS

Fluent

TMG or Thermal Desktop

Job description

As our Senior Thermal Analysis Engineer, you will play a pivotal role in bringing our rocket systems to life. This role will focus on taking parts from concept to production with detailed component and assembly-level analysis including hand‑calculations, FEA models, and testing, ensuring components meet specifications. From mechanical structures (like thrust structures) to electromechanical designs to thermal protection (like heatshields, leading edges), you will ensure that every structure is designed for manufacturability, minimal mass, and high performance. Your analysis, in close collaboration with the design, avionics and fabrication teams, will form the backbone of our rocket’s success.

Own Core Responsibilities

• Identify and solve technical challenges with speed
• Own the sizing of thermal protection systems for all components
• Calculate aerodynamic loads, heat flux and thermal gradients for the analysis team
• Ensure thermal margins of safety calculations meet mission needs
• Develop test plans for Thermal/TVAC/Wind Tunnel, select instrumentation, monitor test activities, and document test data
• Support qualification testing in the lab and correlate models with test results
• Produce & rapidly iterate mechanical concepts designs using structural, thermal, and/or fluids analysis for flight vehicles, engines, and avionics
• Define and document thermal design requirements and subcomponent specifications
• Select and order thermal products that meet mission requirements
• Prepare analysis packages & technical reports
• Provide correlated models and test results to the team

Impacts and Outcomes

• Your flight analysis, in close collaboration with the design, avionics and fabrication teams, will form the backbone of our rocket’s success
• Your ownership of aerodynamic/thermal analysis and products through the design and testing phases of programs will directly support mission success
• Working within established performance standards (quality, safety, schedule, reliability, financial impact) will ensure a high‑quality product, on‑time and within budget, supporting the company’s finances and ability to continue growth at a rapid pace
• By performing analysis, you will identify risks early in the design phase and mitigate risks with smart DFX choices and testing

What You Bring to the Team

• Mechanical, Aerospace, or similar engineering degree from an accredited university
• 6-10 years analysis experience, ideally in an Aerospace environment
• Competence in CAD/CAE software such as NX, FEMAP, Nastran, ABAQUS, Fluent, TMG or Thermal Desktop
• Experience with and expertise in thermal products & sizing
• Experience with instrumentation selection for Thermal and TVAC testing
• Knowledge of COTS thermal products such as MLI, radiators, phase‑change materials or heat sinks
• Demonstrated ability to work in fast‑paced, high‑accountability environments
• Strong communication and collaboration skills
• Ability to work independently and take ownership of products
• Organized, detail‑oriented approach to work and documentation
• Familiarity with industry standards
• Ability to learn new tools, systems, or domains as needed

Bonus Points

• Experience in high‑growth, startup, or technically complex environments
• Proven track record of successful flight hardware design and testing
• Experience with engines and cryogenics

Compensation

Salary Range: $135,000.00 - 165,000.00

The estimated salary range for this role reflects various compensation factors. The final offer depends on factors such as work experience, education, training, key skills, and business needs.

In addition, LEAP provides a comprehensive benefits package for full‑time employees, which includes:

• Equity Program: Equity plan participation is available to all employees following an initial 90‑day employment period and is performance‑based. Equity allocations are determined on a case‑by‑case basis and are not guaranteed. Managers may make recommendations based on individual and team performance. All equity grants are subject to executive review and approval in accordance with the Company’s equity plan.
• Retirement Planning: Save for the future with a 401(k) plan that includes competitive company matching.
• Growth Opportunities: Take advantage of a professional development stipend to advance your skills and expertise.
• Flexible Time Off: Enjoy PTO as needed and holiday breaks to help you balance work and life, including two week long company winter breaks and paid leave to support a family member, bond with a new child, or manage your own health needs
• Remote Work Flexibility: Our team operates on a hybrid model. We expect you to work with your team for specific details on work location.
• Health Benefits: LEAP provides comprehensive medical, dental, and vision coverage at minimal to no cost for employees. Coverage for dependents and HSA are also available.
• Insurance Coverage: We cover basic life and long‑term disability insurance, with options to add extra coverage to ensure peace of mind for you and your family.

LEAP is proud to be an equal‑opportunity employer committed to building a diverse and inclusive workplace in Colorado. Our team brings together exceptionally talented and diverse individuals who are pushing the boundaries of space access and logistics. We welcome all qualified applicants and provide equal consideration for employment regardless of race, color, religion, sex, gender identity, sexual orientation, national origin, disability, Veteran status, age, or any other protected characteristic under federal, state, or local law. This includes individuals with a criminal history, in compliance with applicable regulations. We actively encourage applications from minorities, women, Veterans, and people with disabilities. At LEAP, we strive to create a supportive and welcoming environment throughout the hiring process. If you’re excited about making a real‑world impact in space technology, we want to hear from you!