Thermal Systems Engineer

Prometheus, Inc.; Bloomington (IN); On-site; USD 90,000 - 150,000; Full time

Benefits offered by this job

Medical, dental, and vision insurance

Life and AD&D insurance

401(k) savings plan

PTO/holidays

Job summary

Prometheus Energetics in Bloomington, Indiana seeks an experienced Thermal Systems Engineer to own TPS design and thermal modeling for solid rocket motor programs.

Reporting to the Director of Engineering, you will lead material selection, modeling, testing, and qualification, collaborating across teams while ensuring ITAR/EAR compliance and security clearances.

The role requires 4–10+ years of experience, US citizenship, and the ability to obtain a Secret clearance.

Qualifications

• Bachelor’s degree in a relevant engineering field.
• Thermal Systems Engineer: 4–6 years of TPS/thermal experience.
• Senior Thermal Systems Engineer: 7–10+ years owning TPS design and qualification.
• US Citizenship required; able to obtain security clearance.

Responsibilities

• Lead TPS design, sizing, and qualification for solid rocket motor assemblies.
• Evaluate high-temperature materials, elastomeric liners, and insulations.
• Define integration requirements for TPS into motor cases for thermal margins.
• Balance TPS mass, margin, and manufacturability across programs.
• Develop 1D–3D transient thermal models using Thermal Desktop, ANSYS, or equivalents.
• Provide boundary conditions for coupled thermo-mechanical analyses.
• Plan and execute subscale tests and post-fire evaluations.
• Collaborate with test facilities on instrumentation and data acquisition.
• Mentor junior staff in thermal analysis and ablative materials.
• Ensure ITAR/EAR compliance and safety across design and lab ops.

Skills

TPS design

Thermal modeling

Ablative materials

High-temperature materials

Thermal analysis software

Education

Bachelor's in Mechanical/Aerospace Eng

Tools

Thermal Desktop

SINDA/FLUINT

ANSYS

Abaqus

FIAT/CMA

Python

MATLAB

Job description

LOCATION
Bloomington, Indiana

REPORTS TO
Director of Engineering

EMPLOYMENT
Full-time

FUNCTION
Engineering

TRAVEL
As required

CLEARANCE
Secret Clearance (or ability to obtain; US Citizenship required)

About Prometheus Energetics

Prometheus Energetics is an independent U.S.-based merchant supplier of solid rocket motors and warheads. A joint venture between Kratos Defense & Security Solutions and Rafael Advanced Defense Systems, Prometheus combines U.S. industrial speed and credibility with decades of combat-proven designs, manufacturing know-how, and technical training to deliver field-ready products at scale.

Position Summary

Prometheus Energetics is seeking an experienced Thermal Systems Engineer / Senior Thermal Systems Engineer to own the design, modeling, testing, and lifecycle integration of Thermal Protection Systems (TPS), internal case insulation, and ablative nozzle components. Reporting directly to the Director of Engineering, this role serves as a primary technical authority driving TPS development from initial concept and material characterization through motor qualification and high-rate production.

Solid Rocket Motor (SRM) interiors demand extreme thermal protection solutions capable of withstanding hypergolic/corrosive combustion environments, rapid thermal transients, particle erosion, and alumina slag impingement. The ideal candidate brings 4 to 10 years of hands-on aerothermal, propulsion, or high-temperature materials engineering experience, combining strong computational modeling skills with practical experience in hot-fire analysis, subscale testing, and factory floor integration.

Key Responsibilities

TPS Design & Material Selection

• Lead the design, sizing, and qualification of thermal protection systems for solid rocket motor assemblies, including internal case insulation, elastomeric liners, nozzle ablatives, igniter insulation, and flame barriers.
• Evaluate and select high-temperature material systems: elastomeric compounds (EPDM, NBR, silicone-based rubbers), carbon-phenolic, silica-phenolic, carbon-carbon composites, bulk graphite, and ceramic/silica insulation.
• Define mechanical, adhesive, and chemical compatibility requirements for TPS integration into composite and metallic motor cases, ensuring structural integrity across cure cycles, storage, and operational temperature extremes.
• Evaluate material response phenomena including thermochemical recession, pyrolysis gas generation, char formation, oxidation, and heat soak to maintain motor case structural margins throughout burn and post-burn phases.
• Support scalable manufacturing processes (e.g., tape wrapping, compression molding, hand layup, mandrel winding, and automated insulation placement) to transition designs from prototype to high-rate production.

Thermal Modeling & Analysis

• Develop and maintain 1D, 2D, and 3D transient thermal and ablative response models using industry-standard software (e.g., Thermal Desktop, SINDA/FLUINT, ANSYS Thermal, Abaqus, FIAT/CMA, or equivalent solvers).
• Translate internal ballistic environments, gas chemistry, convective heat transfer coefficients, radiative flux, and slag/particle impingement profiles into robust thermal analysis boundary conditions.
• Conduct trade studies and design optimization to balance TPS mass, thermal margin, structural integrity, and manufacturability.
• Perform sensitivity analyses and model uncertainty assessments to establish reliable flight and ground test design envelopes.
• Provide thermal boundary conditions and temperature distribution fields to structural analysts for coupled thermal-mechanical stress evaluations of motor cases, grains, and nozzles.

Testing, Qualification & Post-Fire Correlation

• Plan, execute, and evaluate subscale screening and material characterization tests (e.g., oxy-acetylene torch, radiant lamp, furnace, and arc-jet testing).
• Collaborate with test facility personnel to define test objectives, instrumentation layout (thermocouples, heat flux sensors, ablation gauges), and data acquisition requirements for static fires and subscale evaluations.
• Perform detailed post-test evaluations on fired hardware including sectioned insulation, nozzle throats, and exit cones measuring char depth, recession profiles, ply degradation, and bond line integrity.
• Correlate analytical thermal models against measured test data to refine material property decks, recession rates, and thermochemical response parameters.
• Lead root-cause investigations and failure analyses (FRACAS/MRB) for thermal or insulation anomalies, such as localized hot spots, unpredicted erosion, bond line debonding, or insulation burn-through.

Cross-Functional Leadership & Program Support

• Work directly with internal ballisticians, structural engineers, materials scientists, and manufacturing teams to deliver fully integrated motor designs on schedule.
• Author clear engineering documentation, including thermal analysis reports, material/process specifications, design verification vectors, and qualification test plans.
• Present technical findings, analysis results, and design rationale at major program milestones (PDR, CDR, PQR, MRB).
• Serve as a technical mentor to junior engineering staff in thermal analysis techniques, ablative material behavior, and testing methodologies.
• Ensure strict compliance with ITAR, EAR, site energetics safety standards, and environmental safety guidelines across all design and lab operations.

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Materials Science & Engineering, Chemical Engineering, or a closely related technical field from an accredited institution.
• Experience:
  • o Thermal Systems Engineer: Minimum of 4-6 years of relevant experience in thermal protection systems, propulsion thermal analysis, or high-temperature materials engineering.
  • o Senior Thermal Systems Engineer: 7-10+ years of progressive engineering experience owning TPS/ablative design and qualification for solid rocket motors or hypersonic systems.
• Proficiency in transient thermal analysis using industry tools (e.g., Thermal Desktop, SINDA/FLUINT, ANSYS, Abaqus, or custom thermochemical/ablative solvers).
• Strong working knowledge of aerothermal fundamentals and high-temperature material behavior (pyrolysis, charring, recession, elastomeric insulation, composite ablators).
• Hands-on experience with high-heat-flux material characterization, test instrumentation, or post-fire hardware sectioning/inspection.
• U.S. Citizenship required (position involves ITAR/EAR restricted technology).
• Ability to obtain and maintain a U.S. Government Secret Security Clearance.

Preferred Qualifications

• Master's Degree or Ph.D. in Aerospace, Mechanical, or Materials Engineering with a focus on thermosciences, hypersonics, or composite material response.
• Direct experience in Solid Rocket Motor (SRM) interior ballistic environment modeling, nozzle ablation analysis, or alumina slag accumulation modeling.
• Familiarity with solid propellant liner/insulation/propellant (LIP) interface chemistry and bonding processes.
• Applied experience with Python, MATLAB, or C/C++ for custom thermal automation, material deck generation, or data extraction scripts.
• Background supporting production transition, supplier quality technical evaluations, or manufacturing nonconformance dispositions (MRB).
• Active U.S. Government Secret Security Clearance.

Work Environment & Physical Requirements

• Work is performed in office, machine shop, laboratory, and energetics manufacturing environments, including high-hazard areas subject to enhanced safety and security controls.
• Must be able to wear required personal protective equipment (PPE) and comply with site safety, explosive-safety, electrostatic discharge (ESD), and access-control requirements.
• Ability to move throughout a manufacturing site, inspect physical tooling, participate in shop-floor audits, and occasionally lift up to 25 pounds.
• Regular, reliable attendance is required. Periodic travel to vendor machine shops, secondary company facilities, or customer sites may be required during startup, tool qualification, or critical production events.

Benefits

• Medical, dental, and vision insurance
• Life and AD&D insurance; short- and long-term disability coverage
• 401(k) savings plan
• Paid time off and company holidays

EQUAL OPPORTUNITY EMPLOYER