Thermal Engineer – Advanced Prototype Systems

Connexion Systems and Engineering, Inc.; Lexington (MA); Hybrid; USD 124,000 - 197,000; Full time

Job summary

Connexion Systems & Engineering seeks a Thermal Engineer to support advanced prototype systems for national security missions across space, air, ground, and underwater platforms.

The role focuses on thermal analysis, modeling, hardware development, integration, and testing across the full engineering lifecycle, with an emphasis on mission-critical thermal management and multidisciplinary collaboration.

Qualifications

• Bachelor’s degree in Thermal, Mechanical, or Aerospace engineering or related field.
• 5+ years of professional thermal engineering experience.
• 5+ years of thermal analysis experience.
• 5+ years of Thermal Desktop — required.
• 5+ years of SolidWorks experience — required.

Responsibilities

• Develop and execute geometry-based thermal models for prototype systems and components.
• Apply thermo-physical and optical material properties; model interfaces.
• Perform steady-state and transient thermal analyses to evaluate temperatures and requirements.
• Provide thermal engineering input for system-level trade studies and design reviews.
• Design and analyze thermal for space-qualified optical/electronics/structures hardware.
• Evaluate and procure thermal control hardware.
• Develop and execute testing plans for developmental and qualification stages.
• Support hardware development, integration, and environmental testing.
• Collaborate across disciplines (structural, mechanical, electrical, optical, systems).
• Travel domestically for meetings and field sites (≈10%).

Skills

Thermal analysis

Engineering design

Thermal modeling

Education

Bachelor’s degree in Thermal/Mechanical/Aerospace engineering

Tools

Thermal Desktop

SolidWorks

ANSYS/COMSOL

Job description

Title: Thermal Engineer – Advanced Prototype Systems

Hiring Organization: Connexion Systems & Engineering

Compensation, Benefits, And Employment Type

• Duration: 3- year contract position
• Pay rate: $60–$95/hour, DOE (higher for exceptional candidates)
• Job Location: Bedford, MA
• Work Model: Hybrid, 4 days onsite, 1 remote
• Security Clearance: must be eligible for Top Secret clearance
• Schedule: Monday – Friday, 1st shift
• Job#: bh19551

Clearance & Location

• Candidates do not need an active security clearance to apply but must be willing and able to obtain a Top Secret clearance after starting.
• This is a 4-day onsite / 1-day remote position in Bedford, MA. Candidates who are not local must be willing to fully relocate to the area at the start of the assignment.

Description

We are seeking a Thermal Engineer to join a highly technical engineering organization developing first-of-a-kind prototype systems supporting complex national security missions across space, air, ground, and underwater platforms.

This is a hands‑on opportunity for an engineer who enjoys working at the intersection of thermal analysis, modeling and simulation, hardware development, integration, and testing. You’ll work as part of a multidisciplinary team and contribute across the full engineering lifecycle—from concept development and system‑level trade studies through prototype development, environmental testing, and on‑orbit testing.

Projects involve advanced thermal management, optical and communication systems, electronics, structures, and aerospace platforms, with challenging performance, size, weight, power, and environmental requirements.

What You’ll Do

• Develop and execute geometry‑based thermal models for prototype systems and components.
• Apply appropriate thermo‑physical and optical material properties and model mechanical, thermal, and radiative interfaces.
• Perform steady‑state and transient thermal analyses to evaluate operating temperatures and mission requirements.
• Provide thermal engineering expertise for system‑level trade studies, architecture decisions, and design reviews.
• Perform detailed thermal design and analysis for space‑qualified optical and communications systems, electronics, structures, and supporting hardware.
• Evaluate, select, and procure thermal control hardware.
• Develop and execute plans for developmental, qualification, and acceptance testing.
• Support hardware development, integration, characterization, and environmental testing.
• Work collaboratively with structural, mechanical, electrical, optical, systems, and other engineering disciplines.
• Contribute to programs spanning platform‑, subsystem‑, and component‑level development and multiple mission phases.
• Occasionally travel domestically to meetings and field sites (approximately 10% or less).

Required Qualifications

• Bachelor’s degree in Thermal Engineering, Mechanical Engineering, Aerospace Engineering, or a related engineering discipline.
• 5+ years of professional thermal engineering experience.
• 5+ years of thermal analysis experience.
• 5+ years of experience with Thermal Desktop — required.
• 5+ years of SolidWorks experience — required.
• Strong understanding of thermal modeling, analysis, and engineering design.
• Ability and willingness to obtain a Top Secret security clearance.

Preferred Qualifications

• Master’s degree in Engineering or a related technical discipline.
• Experience with thermal engineering for space‑based and/or airborne platforms.
• Experience with orbital thermal analysis and modeling the space environment.
• Knowledge of passive and active thermal control techniques, including:
• Heat pipes
• Multilayer insulation (MLI)
• Thermal coatings
• Surface treatments
• Experience developing thermal architectures for space‑based systems.
• Experience with thermal vacuum testing, including test planning and execution.
• Experience with ANSYS and/or COMSOL.
• Experience with Computational Fluid Dynamics (CFD).
• Experience with hardware characterization and environmental/performance testing.

Why This Opportunity?

• Work on advanced prototype systems across space, airborne, ground, and underwater applications.
• Apply thermal engineering expertise to complex, mission‑critical hardware.
• Be involved throughout the engineering lifecycle—not just analysis, but design, hardware development, integration, and testing.
• Collaborate with experienced engineers across multiple technical disciplines.
• Opportunity for technical growth, mentorship, and increasing technical/program leadership.
• Exposure to challenging thermal problems involving cryogenic through hypersonic environments and demanding aerospace applications.