CFD Performance Engineer in Addison, Texas at Firehawk Aerospace Inc

Firehawk is a leading propulsion-focused aerospace and defense company located in Addison, TX. Our innovative approach empowers us to design and manufacture cutting-edge solid and hybrid rocket motors and engines. We aim to push the boundaries of propulsion technology to serve both commercial and defense sectors.

Position Details
Seeking an experienced CFD / Trajectory Sim Engineer to lead analysis, design, and verification of advanced aerospace systems, with a particular emphasis on solid rocket motor performance. You will own end-to-end simulation and control tasks: from internal flow and nozzle CFD to aerodynamic modeling, and trajectory analysis.

This role is ideal for someone who is comfortable switching between detailed physics-based modeling (including propulsion and aerodynamics) and system-level analysis, and who can provide technical leadership on complex, multi-disciplinary projects involving solid rocket motors and flight vehicles.

Key Responsibilities
• Lead aerodynamic and aerothermal analysis for vehicles (e.g., launch vehicles, spacecraft, UAVs, missiles).
o Perform CFD analyses of solid rocket motors, including:
• Internal flow through grain geometry, ports, and chambers.
• Nozzle flow (subsonic, transonic, supersonic) and expansion characteristics.
• Coupled internal/external flow interactions where applicable.
o Develop, run, and validate CFD models for internal and external flows (steady/unsteady, compressible, turbulent, reacting if applicable).
o Generate and manage high-quality meshes (chamber, grain, nozzle, plumes); perform grid convergence, sensitivity, and uncertainty analysis.
o Analyze thrust, specific impulse, nozzle efficiency, and flow-induced loads; provide derived parameters and aero/propulsion databases for GNC and structures.
o Correlate CFD results with static fire test data, wind tunnel data, and/or flight test data; refine models based on discrepancies.
• Trajectory Simulation
o Develop and maintain high‑fidelity trajectory simulation tools for aerospace or defense platforms.
o Model vehicle dynamics, atmospheric effects, propulsion performance, possible guidance and control behavior, and environmental constraints.
o Perform Monte Carlo simulations, sensitivity studies, and performance margin assessments.
o Analyze flight test or experimental data and correlate results with simulation models.
o Generate mission‑level analyses, including launch windows, flight envelopes, aerodynamics, and range safety considerations.
• Systems & Collaboration
o Serve as a technical leader, mentoring junior engineers and reviewing CFD analyses, Trajectory analysis, and code.
o Work closely with propulsion engineers on grain design, performance prediction, and test correlation for solid rocket motors.
o Present findings, risks, and recommendations to engineering leadership and program management.
o Contribute to requirements definition, verification plans, and documentation of models and codes.

Required Qualifications
• Bachelor in Aerospace Engineering, Mechanical Engineering, Applied Physics, or a related field.
• 5+ years of relevant industry or research experience in CFD and/or Trajectory sim for aerospace systems.
• Demonstrated experience with CFD applied to propulsion systems, ideally solid rocket motors (internal flow, nozzle CFD, plume, or related work).
• Strong proficiency with at least one major CFD tool (e.g., ANSYS Fluent, CFX, STAR-CCM+, OpenFOAM, SU2).
• Solid background in fluid dynamics, aerodynamics, and numerical methods (RANS, LES, compressible flow, high Mach regimes).
• Experience with 3 DOF and 6 DOF simulation on launch vehicles.
• Strong skills in MATLAB/Simulink and at least one programming language (Python, C/C++, or Julia).
• Experience with version control (Git), model verification, and rigorous documentation practices.
• Excellent communication skills and ability to clearly explain complex technical topics to multidisciplinary teams.

Preferred Qualifications
• Master or PhD in Aerospace Engineering, Mechanical Engineering, Applied Physics, or a related field.
• Deep experience in solid rocket motor design or analysis, including grain regression modeling, thrust tailoring, or nozzle optimization.
• Experience with high Mach aerodynamics, plume–vehicle interactions, and coupled aero-thermal analysis.
• Experience integrating CFD results (aero and propulsion) into aero/propulsion databases and using them within trajectory/GNC tools.
• Prior experience leading small technical teams or owning a major subsystem (e.g., propulsion + Performance Analysis + GNC integration).

ITAR Requirements:
To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.

Work Environment and Physical Requirements:
Employees in these positions must possess mobility to work in a standard office setting and to use standard office equipment, including a computer; stamina to sit and to maintain attention to detail despite interruptions; may occasionally lift/carry/push/pull up to 25 pounds; may require minimal walking, standing for extended amounts of time, climbing, crouching, and/or bending; and vision to read printed materials and a computer screen, and hearing and speech to communicate in person and over the telephone. May require the ability to travel by air or auto. May require the use of personal protective equipment such as safety glasses, safety shoes, and shop coat.

Security Clearance:
May be required to obtain and maintain a U.S. Security Clearance at the appropriate level. Requires U.S. Citizenship. Must also be able to satisfy federal government requirements for access to government information, and having dual citizenship may preclude you from being able to meet this requirement.

Benefits at Firehawk Aerospace
At Firehawk, we are committed to supporting the well-being of our employees and their families. Our comprehensive benefits package is designed to provide peace of mind and help you thrive both personally and professionally.
Health Coverage: We offer 100% employer-paid medical premiums for employees and up to 75% coverage for dependents under select plans, with additional options for PPO and HDHP plans. Coverage begins the first of the month following your hire date.
Dental and Vision Plans: Affordable dental and vision plans with extensive coverage options, including preventive care, orthodontics, and allowances for contacts and frames.
Employee Assistance Program (EAP): Access to free, confidential services, including counseling, legal consultations, wellness coaching, and virtual concierge services to support your work-life balance.
Flexible Work Schedule: Enjoy a 9/80 schedule option, allowing for greater flexibility and work-life balance.
On-Site Perks: Complimentary snacks and refreshments to keep you energized throughout the day.
Professional Growth: Mentorship opportunities with industry-leading engineers and engagement in cutting-edge projects at the forefront of aerospace innovation.

Equal Opportunity Employer Statement:
Firehawk is an Equal Opportunity Employer; employment with Firehawk is governed on the basis of merit, competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.