Senior Thermal & TPS Integration Engineer
Designs, analyzes, builds, and flight-validates thermal protection systems (heat shields, control-surface protection, internal insulation) for Castelion's long-range hypersonic strike vehicles, hands-on within multidisciplinary teams. Core work spans aerothermal analysis, high-temperature materials, ANSYS/MATLAB thermal-structural analysis, and high-temperature testing like arc-jet or furnace.
- Compensation
- Not disclosed
- Location
- Rio Rancho, United States
- Work setup
- Not specified
- Seniority
- Senior
- Employment
- Full time
- Experience
- 5+ years
- Category
- Software engineering
- Posted
Skills
Must have
- Bachelor's, Master's, or PhD in Aerospace Engineering, Mechanical Engineering, Materials Science, or related field
- 5+ years of experience in thermal protection system design, analysis, and validation for aerospace or high-temperature applications
- Strong background in aerothermal environments, heat transfer, and high-temperature materials
- Experience designing TPS for flight vehicles, including heat shields, control surfaces, or internal insulation systems
- Familiarity with TPS materials such as ceramics, carbon-carbon, ablatives, and insulating blankets
- Experience with seals, gaps, and interface design in high-temperature, moving or constrained systems
- Proficiency in thermal and structural analysis tools (e.g., ANSYS, MATLAB, or equivalent)
- Experience with high-temperature testing methods (e.g., arc-jet, furnace, or similar)
- Experience with hardware build, test, and troubleshooting in a lab or flight hardware environment
- Strong problem-solving mindset, thriving in a fast-paced, hardware-rich, high flight cadence environment
Full description
Castelion was founded to restore America’s ability to field advanced weapons at speed and scale. Inspired by the engineering urgency of the WWII and Apollo eras, we combine rapid iteration, vertical integration, and scalable manufacturing to deliver affordable, high-performance strike systems. Our mission: rebuild industrial agility to strengthen national security and outpace evolving threats.
About the Role:
We are seeking multiple Senior Thermal & TPS Integration Engineers to design and deliver thermal protection solutions for Castelion's long-range hypersonic strike vehicles. These roles are critical to ensuring vehicle survivability and performance in extreme aerothermal environments. You will work hands-on with multidisciplinary engineering teams to design, analyze, build, and validate TPS across the vehicle, including heat shields, control surface protection, and internal thermal insulation systems in a fast-paced, hardware-driven environment.
Requirements
- Bachelor's, Master's, or PhD in Aerospace Engineering, Mechanical Engineering, Materials Science, or related field
- 5+ years of experience in thermal protection system design, analysis, and validation for aerospace or high-temperature applications
- Strong background in aerothermal environments, heat transfer, and high-temperature materials
- Experience designing TPS for flight vehicles, including heat shields, control surfaces, or internal insulation systems
- Familiarity with TPS materials such as ceramics, carbon-carbon, ablatives, and insulating blankets
- Experience with seals, gaps, and interface design in high-temperature, moving or constrained systems
- Proficiency in thermal and structural analysis tools (e.g., ANSYS, MATLAB, or equivalent)
- Experience with high-temperature testing methods (e.g., arc-jet, furnace, or similar)
- Experience with hardware build, test, and troubleshooting in a lab or flight hardware environment
- Strong problem-solving mindset, thriving in a fast-paced, hardware-rich, high flight cadence environment
Benefits
- Employee Equity: Meaningful equity for
all full-time employees - share value has increased 150x in three years
- Personal Time Off: Four (4) weeks of paid
time off to unplug, reset, and come back sharp—velocity matters,
burnout doesn't
- Company Paid Holidays: Ten (10) company
paid holidays
- Medical: We offer plans at 100% employee
covered and 80% of dependent coverage