Sr Analysis Mechanical Engineer (Thermal, Structural)

About the Company:

We are a stealth-mode Aerospace & Defense startup headquartered in Gardena, CA. Our founding team hails from SpaceX, Anduril, and Lockheed Martin, and we are backed by Joint Staff-level military leadership and several Silicon Valley firms. With a world-class business development & leadership team already in place, we are well positioned to capitalize on already overwhelming demand.

About the Role:

We are seeking a highly motivated Senior Analysis Mechanical Engineer specializing in thermal and structural analysis to support the development of advanced aerospace systems and hardware. In this role, you will lead and execute complex structural and thermal analyses for primary and secondary structures, contributing across the full product lifecycle from rapid conceptual design through testing, validation, and operational performance assessment.

You will work closely with multidisciplinary engineering teams to develop finite element models, establish structural load paths, perform preliminary sizing for metallic and composite structures, and conduct detailed thermal analyses using industry-standard tools and methodologies. The position requires strong expertise in FEM/FEA, thermal network analysis, and analytical problem-solving, along with the ability to collaborate in fast-paced development environments with aggressive timelines.

Responsibilities:

• Develop structural analysis tools and guidelines for company-wide use; engage key stakeholders, secure their support, and provide training to engineers as required.
• Conduct structural analyses on primary and secondary structures through finite element modeling (FEM) and manual calculations.
• Establish load paths and perform preliminary structural sizing with metallic and composite materials.
• Collaborate with design teams on rapid conceptual design, modeling, analysis, and test cycles, including CAD development, finite element analysis (FEA), and test oversight.
• Produce high-quality documentation to reduce error rates and enhance operational efficiency.
• Perform peer reviews of engineering models, analyses, and testing procedures.
• Continuously pursue improvements in performance and robustness.
• Execute thermal analysis of hardware, encompassing initial high-level analyses through validation using ground tests, flight data, and orbital performance metrics.

Preferred Skills and Experience:

• Bachelors in Mechanical Engineering or related field with analysis concentration
• Minimum 5 years of professional experience in thermal or fluid analysis.
• Solid understanding of spacecraft and/or launch vehicle systems.
• Proficient with thermal network analysis.
• Experienced in using ANSYS Workbench.
• Familiar with scripting languages, particularly Python.
• Exceptional written and verbal communication skills.
• Proven ability to meet aggressive timelines.
• Master's in engineering, mathematics, or physics.
• Prior experience conducting structural analysis on primary structures.
• Proficient with finite element analysis (FEA) solvers such as ABAQUS, ANSYS, or Nastran.
• Advanced proficiency with pre- and post-processing software including ABAQUS/CAE, ANSA/META, ANSYS, or FEMAP (including scripting capabilities).
• Familiarity with nonlinear analyses related to material behavior, geometry, and contact.
• Experience conducting stress analyses of welded structures, addressing heat distortion and residual stresses.
• Strong knowledge of fatigue and fracture mechanics, with familiarity in fatigue and crack-growth analysis tools such as nCode, NASGRO, or equivalent software.
• Competency with scripting using Python, VBA, or Matlab.
• Strong communication skills with the capability to clearly and concisely present recommendations.
• Self-motivated with the willingness to independently tackle new challenges and effectively manage multiple tasks concurrently

ADDITIONAL REQUIREMENTS:

Itar:

To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State.