Senior Thermal Structural Analysis Engineer

Insider, Inc.; Bothell (WA); On-site; USD 80,000 - 120,000; Full time

Benefits offered by this job

Comprehensive medical, vision, and dental coverage

2-3 weeks of paid vacation

Employee Stock Purchase Plan

Job summary

Insider, Inc. is seeking a Thermal-Structural Analysis Engineer in Bothell, Washington. The role involves developing coupled thermal-structural analyses for spacecraft structures in high-temperature environments. You'll work with various teams to ensure structural integrity during qualification and flight.

The ideal candidate has a BS or MS in Aerospace or Mechanical Engineering and 2-5 years of relevant experience, including proficiency in FEM and programming skills.

Qualifications

• 2-5 years of experience in thermal-structural analysis for aerospace systems.
• Experience performing coupled thermal-structural analyses.
• Proficient in Python or MATLAB for automation and reporting.

Responsibilities

• Develop coupled thermal-structural finite element models.
• Evaluate high-temperature material behavior and structural performance.
• Support verification of propulsion-adjacent hardware.

Skills

Thermal-structural analysis

Finite Element Modeling (FEM)

Python programming

MATLAB

Version control (Git)

Education

BS or MS in Aerospace Engineering, Mechanical Engineering, or related

Tools

FEMAP/Nastran

Siemens Simcenter 3D

Job description

The Thermal-Structural Analysis Engineer is responsible for substantiating spacecraft structures operating in high-temperature and thermally severe environments. This role owns coupled thermal‑structural analyses used to evaluate stress, deformation, and margin of safety for propulsion‑adjacent and elevated‑temperature hardware. The position works closely with propulsion, thermal, materials, and test teams to ensure structural integrity is maintained across qualification and flight environments.

Responsibilities

Primary Responsibilities – Thermal-Structural Substantiation

• Develop and maintain coupled thermal‑structural finite element models for spacecraft hardware operating in elevated‑temperature environments
• Perform thermo‑mechanical stress, distortion, fatigue, and margin of safety analyses driven by thermal gradients and transient heating
• Evaluate high‑temperature material behavior and structural performance using analysis and first‑principles hand calculations
• Partner with propulsion, thermal, and design teams to validate and optimize structural designs for strength, stiffness, weight, and thermal durability
• Support structural verification of propulsion‑adjacent and thermally driven hardware through qualification and flight readiness
• Define, execute, and interpret elevated‑temperature material strength testing to characterize mechanical properties and support thermo‑mechanical structural verification

Additional Responsibilities – Testing, Correlation & Automation

• Define and support elevated‑temperature material and structural test campaigns to characterize thermo‑mechanical behavior
• Correlate analytical predictions with high‑temperature test data and resolve discrepancies using first‑principles reasoning
• Develop Python‑based tools to automate coupled analysis post‑processing, reporting, and verification workflows
• Contribute to documentation of thermal‑structural assumptions, methods, and verification rationale

Basic Qualifications

• 2–5 years of experience in thermal‑structural or thermo‑mechanical analysis for aerospace systems
• Experience performing coupled thermal‑structural stress, deformation, and margin of safety analyses
• Proficiency developing and maintaining coupled thermal‑structural FEMs using FEMAP/Nastran or Siemens Simcenter 3D
• Experience evaluating elevated‑temperature material behavior and structural performance
• Experience supporting propulsion or thruster‑adjacent hardware operating in high‑temperature environments
• Proficiency with Python and/or MATLAB for analysis automation, data reduction, and reporting
• Experience using version control systems such as Git in an engineering analysis environment
• BS or MS in Aerospace Engineering, Mechanical Engineering, or a related engineering discipline

Preferred skills & Experience

• Strong ability to perform coupled thermal‑structural analysis for spacecraft hardware in elevated‑temperature environments
• Deep understanding of thermal gradient‑driven stress, distortion, and failure mechanisms
• Ability to model, interpret, and validate high‑temperature material behavior within structural analyses
• Proficiency in using first‑principles hand calculations to bound and verify coupled FEM results
• Ability to correlate thermo‑mechanical analysis with high‑temperature test data and resolve discrepancies
• Clear technical communication skills for documenting assumptions, methods, and verification rationale

Compensation & Benefits

Base salary is just one part of your total rewards package at Portal. You may also be eligible for long‑term incentives in the form of company stock, stock options, or long‑term cash awards, as well as potential discretionary bonuses and the ability to purchase additional stock at a discount through an Employee Stock Purchase Plan. You will also receive access to comprehensive medical, vision, and dental coverage. Portal is planning to establish future access to a 401(k) retirement plan, short & long‑term disability insurance, life insurance, and various other discounts and perks. Employees typically have 2-3 weeks of paid vacation per year plus company holidays.

ITAR Requirements

To conform to U.S. Government export regulations, the applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State.