Thermal Engineer Jobs

Job Description
We are seeking a highly experienced Structural & Thermal Analysis Engineer to support advanced defense, aerospace, and mission-critical electronic systems across Aerospace & Mission Systems (AMS).
This role serves as a recognized technical authority and subject matter expert in structural, thermal, and dynamic analysis, responsible for influencing product development, engineering strategy, and analytical excellence across multiple programs and business areas. The successful candidate will possess deep expertise in finite element analysis, dynamics, vibration, shock, heat transfer, electronics cooling, and solver methodologies, with the ability to develop technically sound solutions to exceptionally complex engineering challenges.

The candidate will provide technical leadership throughout the hardware development lifecycle, from early architecture and trade studies through detailed design, qualification, production, and sustainment. A strong understanding of defense acquisition practices, military qualification requirements, and phase review processes is essential, along with the ability to evaluate technical risk and influence key engineering decisions.

As the organization's structural and thermal analysis authority, this individual will establish and govern analytical methodologies, modeling standards, validation approaches, and best practices used across the Mechanical Analysis Capability Group and AMS. You will serve as an independent technical reviewer, consultant, and escalation authority for critical engineering issues while providing guidance to engineering leadership, chief engineers, program teams, and customers.

Key Responsibilities:

• Serve as the organization's recognized subject matter expert and technical authority for structural and thermal analysis of defense electronics, EO/IR systems, RF hardware, avionics, and mission-critical products.
• Influence product architectures, design decisions, technology roadmaps, and long-range engineering strategy through early lifecycle analysis, risk assessment, and technical consultation.
• Lead the resolution of exceptionally complex structural, thermal, vibration, shock, fatigue, and electronics reliability challenges through the development and application of advanced analytical methods and simulation technologies.
• Provide independent technical oversight and approval of finite element modeling approaches, assumptions, validation methods, and analytical conclusions for high-consequence engineering decisions.
• Chair the Structural and Thermal Analysis Review Board, establishing and enforcing expectations for technical rigor, documentation quality, model credibility, validation requirements, and engineering excellence across AMS programs.
• Define, standardize, and adjudicate structural and thermal analysis methodologies, best practices, validation approaches, and engineering standards utilized across the Mechanical Analysis Capability Group and AMS.
• Serve as the independent technical consultant and final escalation authority for complex structural and thermal engineering issues, providing guidance to engineering leadership, chief engineers, program teams, and customers.
Lead organizational capability development through establishment of analysis standards, training strategies, tool roadmaps, and investments that advance AMS engineering effectiveness.

Required Education, Experience, & Skills

• Bachelor's Degree in Mechanical Engineering, Aerospace Engineering, or a related engineering discipline and 12+ years of relevant experience, or an equivalent combination of education and experience.
• Extensive experience leading structural and thermal analysis activities for defense, aerospace, avionics, EO/IR, RF/microwave, or other mission-critical electronic systems.
• Recognized expertise in finite element analysis (FEA), including modal, vibration, shock, static, nonlinear, fatigue, and thermal analysis methodologies.
• Demonstrated ability to develop, validate, and implement advanced structural and thermal analysis approaches for complex engineering challenges where requirements, constraints, or solution paths may be ambiguous.
• Deep understanding of electronics packaging, circuit card assemblies, chassis and enclosure design, thermal management architectures, and reliability considerations for ruggedized defense electronics.
• Demonstrated understanding of defense acquisition environments, military qualification requirements, and customer expectations associated with DoD programs.
• Proven ability to influence technical direction and engineering decisions across multiple programs, product lines, or business areas.
• Experience serving as an independent technical reviewer, consultant, or escalation authority for complex engineering issues.
• Demonstrated ability to communicate complex technical concepts and recommendations to customers, chief engineers, engineering leadership, and executive stakeholders.
• Eligibility to obtain and maintain a U.S. DoD Secret Security Clearance.

Preferred Education, Experience, & Skills

• Master's Degree or PhD in Mechanical Engineering, Aerospace Engineering, or a related discipline.
• Active Secret or Top Secret security clearance.
• 20+ years of experience supporting defense, aerospace, or national security programs.
• Expertise with Siemens Simcenter 3D/NX, NASTRAN, ANSYS Mechanical, ANSYS Icepak, Abaqus, LS-DYNA, HyperMesh, OptiStruct, or equivalent simulation environments.
• Extensive experience with structural and thermal design of mission-critical electronic systems, including electronics cooling, vibration survivability, thermal fatigue, solder-joint reliability, and environmental durability.
• Experience with STOP (Structural, Thermal, Optical Performance) analysis, SigFit, precision EO/IR systems, RF/microwave hardware, or high-performance electro-mechanical systems.
• Experience developing engineering standards, organizational best practices, model validation requirements, or analysis governance processes adopted across multiple programs or business areas.
• Demonstrated leadership of organization-wide analysis governance activities, including methodology development, independent technical reviews, capability advancement, and establishment of engineering standards across multiple programs.
• Experience chairing or leading cross-program technical review boards, independent design reviews, model credibility reviews, or engineering governance activities.
• Recognized technical leadership through major enterprise contributions, publications, patents, conference presentations, customer recognition, or adoption of engineering methods across a broad organization.

Pay Information
Full-Time Salary Range: $153377 - $260743

Please note: This range is based on our market pay structures. However, individual salaries are determined by a variety of factors including, but not limited to: business considerations, local market conditions, and internal equity, as well as candidate qualifications, such as skills, education, and experience.

Employee Benefits: At BAE Systems, we support our employees in all aspects of their life, including their health and financial well-being. Regular employees scheduled to work 20+ hours per week are offered: health, dental, and vision insurance; health savings accounts; a 401(k) savings plan; disability coverage; and life and accident insurance. We also have an employee assistance program, a legal plan, and other perks including discounts on things like home, auto, and pet insurance. Our leave programs include paid time off, paid holidays, as well as other types of leave, including paid parental, military, bereavement, and any applicable federal and state sick leave. Employees may participate in the company recognition program to receive monetary or non-monetary recognition awards. Other incentives may be available based on position level and/or job specifics.



About BAE Systems, Inc.
BAE Systems, Inc. is a defense, aerospace, and security company headquartered in Falls Church, Virginia, with more than 40,000 employees worldwide. We serve, supply, and protect those who protect us. As one of the most geographically diverse international defense companies, we deliver a full range of products and services spanning air, land, maritime, space, and cyber, including advanced electronics, intelligence solutions, and dedicated customer support.

Our culture is performance-driven and values-led, built on curiosity, creativity, and collaboration. Purpose isn't a tagline here. It's what drives us. We're developing breakthrough technologies that defend national security and make a lasting impact on our communities and our planet. When you join BAE Systems, you're not just building a career. You're contributing to a mission that truly matters.

This position will be posted for at least 5 calendar days. The posting will remain active until the position is filled, or a qualified pool of candidates is identified.