Thermal Analyst - Thermal Protection Systems Engineer with Security Clearance

Aurex; Huntsville (AL); On-site; USD 135,000 - 150,000; Full time

Job summary

Aurex, a Huntsville-based mission-focused aerospace and defense company, seeks a Thermal Analyst with extensive experience in thermal analysis of spacecraft, launch vehicles, and TPS. You will build high-fidelity models, size ablative and reusable TPS, and evaluate material response across ground, ascent, orbital, and entry phases.

Collaborate with aerothermal and structural teams on multiphysics problems, analyze orbital environments, and validate models against test or flight data.

Qualifications

• 3–7 years of thermal analysis experience in aerospace roles.
• Experience with thermal protection systems and ablative/reusable TPS sizing.
• Proficiency with Thermal Desktop (Ansys) and SINDA/FLUINT.
• Strong understanding of radiative, conductive, and convective heat transfer.
• Ability to correlate models with test or flight data.

Responsibilities

• Perform system- and component-level thermal analyses across flight phases.
• Develop and maintain detailed thermal models for spacecraft TPS.
• Analyze orbital environments and predict temperatures and gradients.
• Couple aeroheating data with material response models.
• Support thermal-structural interfaces and heater/MLI design.
• Collaborate with aerothermal and structures teams on multiphysics problems.
• Document analyses and correlate models to data.

Skills

Thermal analysis

Multiphysics coupling

Aerospace engineering

Thermal Desktop (Ansys)

SINDA/FLUINT

TPS sizing & ablation tools

Heat transfer (radiation, conduction,

CFD aeroheating data integration

Problem solving

Teamwork & communication

Education

Bachelor's degree in Mechanical or Aerospace Engineering

Master's degree or Ph.D. in related field

Tools

FIAT

CHAR

TITAN/3dFIAT

Icarus

Nastran

Abaqus

ANSYS

Job description

Thermal Analyst - Thermal Protection Systems Engineer Huntsville, AL

Who We Are

Aurex is a mission-focused aerospace and defense company building the next frontier of deterrence. From hypersonics and missile defense to hardened networks and orbital systems, we design, test, and deliver the platforms that turn unproven ideas into battlefield-ready capability. Born in Huntsville and built for speed, Aurex brings together aerospace veterans, combat-tested operators, and forward-leaning technologists to solve problems that matter-fast. We move from whiteboard to warfighter with precision, clarity, and zero tolerance for fluff.

Job Summary

We are looking for a Thermal Analyst with extensive experience in thermal analysis of spacecraft, launch vehicles, and thermal protection systems. The ideal candidate will perform system-level and component-level thermal analysis across ground, ascent, orbital, and atmospheric entry phases, develop high-fidelity thermal models, size ablative and reusable TPS, and evaluate material response and in-depth temperatures. Proficiency with industry-standard thermal analysis tools is required, with a primary focus on accurate thermal predictions, TPS design, and multiphysics collaboration.

Responsibilities

• Perform system-level and component-level thermal analysis for orbital vehicles, re-entry vehicles, and TPS across ground, ascent, orbital, and atmospheric entry phases.
• Develop and maintain detailed thermal models using industry-standard tools; size ablative and reusable TPS; evaluate material response, recession, and in-depth temperatures.
• Analyze orbital thermal environments (solar, albedo, planetary IR, eclipse cycling, attitude-dependent heating) and their effects on spacecraft structures and avionics, including temperature predictions, thermal gradients, hot/cold cases, and thermal stress implications.
• Utilize aeroheating environments and couple them with material response tools for integrated TPS design and trajectory-based analysis.
• Support thermal-structural interfaces, avionics thermal control, heater/MLI design, active thermal control, and verification activities.
• Collaborate closely with aerothermal (CFD) and structural dynamics teams on multiphysics problems involving high heating rates, shock, vibration, and high-G loads.
• Document analyses, support peer reviews, and correlate models to test or flight data.

Basic Qualifications

• Active DoD Secret Clearance
• Work in person at our corporate headquarters in Huntsville, AL.
• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related field with relevant industry experience
• Master's degree or Ph.D. in Mechanical Engineering, Aerospace Engineering, or a relevant field with experience applying knowledge to real-world systems
• 3-7 years of industry experience in thermal analysis and thermal protection systems for aerospace vehicles.
• Hands-on experience with Thermal Desktop (Ansys) / SINDA/FLUINT for building and running CAD-based spacecraft thermal models.
• Proficiency with TPS / ablation tools such as FIAT, CHAR, TITAN/3dFIAT, Icarus, or equivalent codes for charring ablator response, TPS sizing, and recession modeling.
• Strong background in multi-mode heat transfer (radiation, conduction, convection) for terrestrial, ascent, orbital, and re-entry environments.
• Experience analyzing orbital thermal effects on spacecraft structures and avionics, including temperature mapping, thermal cycling, and gradient-driven stresses.
• Ability to integrate aeroheating data from CFD or engineering methods into thermal and material response models.
• Excellent problem-solving skills and ability to interpret complex thermal simulation results and correlate models to test or flight data.
• Strong communication and teamwork skills to collaborate with multidisciplinary aerospace teams (aerothermal, structures, avionics, and systems engineering).

Preferred Qualifications

• Familiarity with coupling thermal models to structural FEA (Nastran, Abaqus, Ansys) under dynamic environments (shock, vibration, high-G) and thermal-structural interaction.
• Knowledge of active thermal control hardware (heat pipes, pumped loops, heaters) and MLI design for vehicle-level and avionics thermal management.
• Experience with high-heating-rate re-entry or hypersonic thermal environments.
• Background in test correlation and validation of thermal models using experimental or flight data.

How You Will Be Rewarded

• The salary range for this role is $135,000 - $150,000.00 per year.
• We offer a comprehensive total rewards approach to compensation, providing incentives and benefits that extend far beyond the base salary. Compensation is determined by the candidate's work experience, education, training, and relevant skills.
• We offer a competitive benefits package designed to support our employees' health, well-being, and professional growth.
• Location: Huntsville, AL

Aurex is an Equal Opportunity Employer. It prohibits discrimination, retaliation, or any type of harassment on the basis of race, color, religion, gender, gender identity or expression, sexual orientation, national origin, genetics, disability, age, veteran status, citizenship, immigration status, or any other legally protected status in employment, including in hiring, firing, and recruiting decisions. All applicants must be authorized to work lawfully in the United States for positions at Aurex. There may be limited circumstances in which a law, regulation, executive order, or government contract would require certain citizenship; only in those limited circumstances would Aurex require certain citizenship status to comply with the relevant law, regulation, executive order, or government contract applicable to that position. For all other positions, Aurex does not consider an applicant's citizenship but only requires that the applicant be authorized to work lawfully in the United States. If a position is one that falls under export control laws and regulations requiring authorization from the U.S. government to access export-controlled items, any hiring is contingent on the applicant passing the export compliance assessment, which is separate from the I-9 process, for that specific position. A background check will be required prior to any hire. Elevate your career by joining the Aurex Platform, a leader in aerospace innovation PI287151359