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 matterfast. 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.
- One of the following:
- 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
- 37 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.
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