Thermal Engineer

SGS Consulting; Lexington (VA); Hybrid; USD 90,000 - 130,000; Full time

Job summary

SGS Consulting seeks a Thermal Engineer in Lexington, MA to lead end-to-end thermal analyses for defense-related optical and communication systems. You will develop geometry-based models, apply thermo-physical properties, and work with Thermal Desktop, ANSYS, COMSOL, and SolidWorks in a hands-on environment.

The role involves collaborating with an interdisciplinary team, traveling up to 10% domestically, and supporting hardware testing, design reviews, and qualification activities through

Qualifications

• 3+ years in thermal engineering
• Experience with geometric thermal models
• Strong communication and teamwork skills

Responsibilities

• Develop geometry-based thermal models and apply thermo-physical properties
• Perform steady-state and transient thermal analyses for optical and communication systems
• Evaluate thermal control hardware and support testing and qualification activities
• Collaborate with interdisciplinary teams across program lifecycle

Skills

Thermal analysis

Team collaboration

Problem solving

Tools

Thermal Desktop

COMSOL

Ansys

SolidWorks

Job description

Job Title: Thermal Engineer

Duration: 3+ years

Client: Defense Research Lab

Location: Lexington, MA 02421 (onsite 4 days/wk)

Description:

Strong background and experience with using commercial thermal analysis software tools including Thermal Desktop, Ansys, COMSOL, CAD software, and experience with environmental testing. Responsible for developing geometry based thermal models, applying physical and optical properties, accounting for critical mounting interfaces, application of dissipative heat loads, and executing thermal analyses to insure safe operating temperature levels. Supports decision making in the system design architecture and overall thermal management, evaluate/select/procure thermal control hardware, and participate in the preparation and performance of developmental and qualification testing. Carries out system-level and detailed thermal design, analysis, and testing on optical and communication systems including supporting electronics. Projects range from platform level analyses to sensor assembly to detailed components.

Background/Need:

The Group develops first-of-a-kind prototype systems across underwater, ground, air, and space domains for high-impact national security missions. Engineers work on advanced structural and material systems for space-based imaging and laser communications, thermal management solutions from cryogenic to hypersonic regimes, and aerodynamic design and assessment for unmanned aerial vehicles, airborne pods, and hypersonic platforms. Solutions are realized through the integration of high-fidelity analytical and computational modeling, multidisciplinary simulation, environmental testing, and advanced materials, addressing demanding performance, size, weight, power, and environmental constraints that are at the forefront of current engineering capabilities.

The Group offers a collaborative, hands-on environment where engineers pair deep analytical expertise with direct ownership of hardware development, integration, and testing. Engineers are supported in their growth through mentorship and opportunities for increasing technical and programmatic leadership, participation in conferences and professional societies, and direct engagement with mission partners and government sponsors.

Thermal Engineering expertise is required to support the prototyping efforts that span these ranges of applications. Engineering solutions are developed through the utilization of appropriate technologies coupled with high-fidelity models and multidisciplinary simulations, environmental and performance characterization testing, and the utilization and development of advanced materials to optimize solutions to meet ever increasing performance, size, weight, and environmental challenges.

Other information relevant to the job requirement?

• The successful candidate will be part of an interdisciplinary engineering team contributing to the development of operational prototype hardware, spanning the full program life cycle from concept development to on-orbit test. The position may have some infrequent travel to meetings and field sites (probably like 10% of the time or less - domestic travel only).
• Responsible for the end-to-end development and execution of geometry-based thermal models, identifying and applying appropriate thermo-physical and optical material properties, modeling critical mechanical, thermal, and radiative interfaces, applying representative dissipative heat loads, and executing steady-state and transient thermal analyses to ensure compliance with safe operating temperature limits and mission requirements.
• Provide thermal technical expertise to system-level trade studies and design reviews, supporting decision-making related to the overall system architecture and associated thermal management concepts and approaches. Evaluate, select, and procure thermal control hardware, and develop and execute plans for developmental, qualification, and acceptance testing.
• Carry out system-level and detailed component-level thermal design, analysis, and testing on a variety of space-qualified optical and communication systems, as well as their supporting electronics and structures. Projects span platform-, subsystem-, and component-level efforts across multiple programs and mission phases.

Requirements:

• Expertise in commercial thermal analysis software (Thermal Desktop required; in addition, COMSOL and/or Ansys desired) and CAD software (SolidWorks) is required..

Preferred Qualifications:

• Experience with thermal engineering for space and airborne platforms is preferred, including orbit-based thermal analyses and an understanding of passive and active thermal control techniques, including heat pipes, multilayer insulation (MLI), thermal coatings, and surface treatments.
• Significant experience with developing thermal architectures for space-based systems, including a background with modeling and simulation of the space environment, orbital analysis, as well as hardware characterization testing is desired.

Others:

• Clearance: Worker can start with an interimbut will need to clear up to Top Secret after starting.
• Work Location: Work schedule will be 4 days onsite and one day remote.
• Interview Process: Initial screening, Zoom with 1-2 managers and an onsite for a final interview. The team will consider a third zoom round if the candidate is not local at the time of the interview. Any non-local candidate would need to fully relocate at the start of the position to be considered.