Thermal Analyst - Thermal Protection Systems Engineer in Huntsville, Alabama at Aurex

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 matter—fast. We move from whiteboard to warfighter with precision, clarity, and zero tolerance for fluff.

Job Overview

We are seeking an experienced thermal analyst with a strong background in spacecraft and launch vehicle thermal control and thermal protection systems (TPS). Ideal candidates will have direct experience from organizations such as NASA Marshall Space Flight Center’s Spacecraft & Vehicle Systems Department, Thermal Analysis and Control Branch (EV34), or equivalent industry/government teams supporting ascent, orbital, and re-entry environments.

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.
• Generate 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.

Qualifications

• Only U.S. citizen with the ability to obtain a security clearance will be considered.
• Work in person at our corporate headquarters in Huntsville AL
• Minimum experience:
  • Bachelor's degree in Mechanical Engineering, Aerospace Engineering, or a related field with relevant experience in the industry
  • Master's degree or Ph.D. in Mechanical Engineering, Aerospace Engineering, or relevant field with experience in applying your knowledge to real-world systems
• 3-7 years of industry experience in electrical design and development
• 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).

Required Skills & Experience

• Thermal Desktop (Ansys) / SINDA/FLUINT: Hands-on experience building and running CAD-based spacecraft thermal models for orbital environments, radiation, conduction, fluid networks, ascent heating, and basic ablation/recession analysis.
• TPS / ablation tools: Proficiency with FIAT, CHAR, TITAN/3dFIAT, Icarus, or equivalent codes for 1-D to 3-D charring ablator response, TPS sizing, material decomposition, and recession modeling on re-entry vehicles.
• Strong background in multi-mode heat transfer (radiation, conduction, convection) for terrestrial, ascent, orbital, and re-entry environments, including thermal protection system design and analysis.
• Experience analyzing orbital thermal effects on spacecraft structures and avionics, including temperature mapping, thermal cycling impacts, gradient-driven stresses, and avionics hot/cold case predictions.
• Ability to work with aeroheating data from CFD or engineering methods and integrate results into thermal/material response models.
• Experience documenting analyses, supporting peer reviews, and correlating models to test or flight data.

Preferred Qualifications:

• Familiarity with coupling thermal models to structural FEA (Nastran, Abaqus, Ansys) under dynamic environments (shock, vibe, high-G) and thermal-structural interaction.
• Knowledge of active thermal control hardware (heat pipes, pumped loops, heaters) and MLI design for both vehicle-level and avionics thermal management.

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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