Thermal Analysis Engineer (Multiple Levels)

Job Description

Job Description

Position Overview

Onyx Aerospace is seeking Thermal Analysis Engineers at multiple experience levels to support advanced aerospace, defense, and national security programs involving spacecraft, missile systems, strategic deterrence platforms, hypersonic systems, launch vehicles, and mission-critical aerospace hardware.

These positions are responsible for developing, executing, and documenting thermal analyses used to evaluate system performance throughout the lifecycle of advanced aerospace and defense systems operating in demanding terrestrial, atmospheric, and space environments.

We are seeking candidates ranging from experienced individual contributors to senior technical leaders with expertise in thermal modeling, thermal control system design, heat transfer analysis, and environmental characterization. The ideal candidate possesses a strong background in thermal engineering, aerospace system development, and hands-on experience using Thermal Desktop® , SINDA/FLUINT®, and associated analysis tools.

Engineers will work closely with systems engineering, structures, propulsion, avionics, manufacturing, and mission analysis teams to develop thermal solutions supporting critical national defense capabilities and advanced aerospace technologies.

Key Responsibilities

Thermal Analysis & Modeling

• Develop detailed thermal mathematical models using Thermal Desktop® and associated analysis tools.
• Perform steady-state and transient thermal analyses for aerospace and defense systems.
• Analyze conductive, convective, and radiative heat transfer environments.
• Model thermal environments associated with missile systems, spacecraft, launch vehicles, airborne systems, and ground-based defense platforms.
• Evaluate thermal performance throughout mission phases and operational scenarios.

Thermal Control System Design

• Support development and optimization of thermal control architectures.
• Evaluate passive and active thermal control approaches including:
  • Thermal coatings
  • Multi-layer insulation (MLI)
  • Heat pipes
  • Radiators
  • Thermal straps
  • Active cooling systems
• Support design trades involving performance, mass, reliability, and mission risk.

Verification & Validation

• Support thermal test planning and execution.
• Correlate analytical models with test data.
• Support thermal vacuum, environmental, and qualification test campaigns.
• Document model assumptions, methodologies, and results.

Systems Integration

• Collaborate with multidisciplinary engineering teams to ensure thermal requirements are incorporated into system designs.
• Support technical reviews, customer briefings, and design assessments.
• Contribute to system-level trade studies and risk evaluations.

Documentation & Reporting

• Prepare technical reports, presentations, and customer deliverables.
• Maintain thermal models and associated engineering documentation under configuration control.

Experience Levels

Thermal Analysis Engineer

• 5+ years of thermal analysis experience.
• Capable of independently developing and executing thermal models and analyses.
• Supports subsystem and component-level thermal design activities.

Senior Thermal Analysis Engineer

• 10+ years of thermal analysis experience.
• Leads major thermal analysis efforts and supports thermal architecture development.
• Provides technical guidance to junior engineers and supports customer engagement activities.

Principal Thermal Analysis Engineer

• 15+ years of thermal analysis experience.
• Recognized expert in aerospace thermal engineering.
• Leads thermal design trades, thermal control system development, and major analysis efforts across programs.

Thermal Subject Matter Expert

• 20+ years of thermal analysis experience.
• Industry-recognized authority in aerospace thermal engineering and environmental analysis.
• Provides strategic technical leadership across multiple programs and advises senior leadership and customers on thermal design approaches, risk reduction, and technology development.

Required Qualifications

• Bachelor's degree in:
  • Aerospace Engineering (preferred)
  • Mechanical Engineering (preferred)
  • Engineering Physics
  • Or closely related engineering discipline
• Minimum 5 years of thermal analysis experience.
• Demonstrated experience using:
  • Thermal Desktop®
  • SINDA/FLUINT®
  • RadCAD® or equivalent radiation analysis tools
• Strong understanding of:
  • Heat transfer fundamentals
  • Thermal control systems
  • Radiation heat transfer
  • Aerospace thermal environments
  • Thermal testing and model correlation
• U.S. Citizenship required.

Preferred Qualifications

• Master's degree or Ph.D. in Aerospace Engineering, Mechanical Engineering, or related discipline.
• Experience supporting:
  • National Security Space programs
  • Missile Defense Agency programs
  • Strategic deterrence systems
  • Missile and hypersonic vehicle development
  • Space domain awareness systems
  • Launch vehicle development
  • DoD research and development programs
• Experience with:
  • thermal analysis
  • Cryogenic systems
  • High-temperature aerospace systems
  • Thermal vacuum testing
  • Model correlation and validation
• Programming experience using:
  • Python
  • MATLAB
  • VBA or other automation tools
• Ability to obtain and maintain a security clearance.

Additional Information

This position may support programs contingent upon customer funding, contract award, or mission authorization. Employment offers, start dates, and job assignments are dependent on the successful award and continuation of the contract. Candidates must be able to meet applicable background screening, export control, and customer access requirements. Specific assignments and technical responsibilities may vary based on individual qualifications, experience level, customer requirements, and program needs.