Senior Thermal Analyst - Huntsville, AL

Date Posted: 2026-08-13 | Location: Huntsville, AL (315 Bob Heath Dr) | Onsite role | U.S. citizenship required to obtain and maintain a DoD Secret security clearance; active and transferable clearance required prior to start date.

About the Role

The Mechanical Analysis and Test (MA&T) Department ensures structural and thermal design robustness across the Raytheon portfolio. From preliminary concepts to fielded weapon system support, MA&T delivers innovative structural and thermal engineering solutions using classical, empirical, and state-of-the-art finite element methods, validated through cost-effective testing.

As a mid-level Senior Thermal Analyst, you will perform detailed thermal analysis throughout the product lifecycle—from initial design trade studies and proposals to qualification testing and production support. This role involves solving complex thermal challenges, presenting findings to internal and external stakeholders, and leading analysis and test teams.

Responsibilities

• Perform hand calculations to scope higher-detail analysis models.
• Conduct detailed thermal analyses to address program-specific thermal challenges.
• Generate test plans to validate analyses and verify hardware compliance with customer requirements.
• Analyze test data to validate and correlate thermal models.
• Collaborate with experienced analysts on moderate-complexity problems under program cost and schedule constraints.
• Review work with peers to ensure technical accuracy and present results to internal, external, and government customers.
• Document and archive work for future reference.
• Act as a technical leader, refining or developing MA&T department processes and tools, and/or lead analysis/test teams.
• Plan and support thermal testing, including data reduction and model correlation.

Requirements

• Degree in Science, Technology, Engineering, or Mathematics (STEM); ABET-accredited preferred.
• Minimum of 5 years of relevant experience in thermal analysis (unless prohibited by local laws/regulations).
• Experience with thermal analysis tools such as FloTHERM, PATRAN, Thermal Desktop/SINDA, ANSYS, or equivalent.
• Proficiency in mechanical principles to solve classical thermal analysis problems both inside and outside finite element tools.
• Ability to work independently and manage multiple priorities.
• Active and transferable DoD Secret security clearance (U.S. citizenship required).
• Demonstrated experience in thermal testing: planning, execution, data reduction, and model correlation.

Preferred Qualifications

• Degree in Mechanical or Aerospace Engineering.
• 5+ years of professional experience in thermal analysis of complex systems requiring cross-disciplinary collaboration.
• Experience with solid modeling CAD tools (e.g., CREO or equivalent).
• Expertise in electronics cooling and aerodynamic heating analyses.
• Experience presenting to external customers.
• Demonstrated leadership in leading thermal analysis teams or thermal testing, including model correlation.
• Ability to travel to government and other facilities for program support.
• Advanced degree in a relevant discipline.

Benefits

• Medical, dental, vision, life, and disability insurance.
• 401(k) match and flexible spending accounts.
• Flexible work schedules and employee assistance program.
• Employee Scholar Program for educational assistance.
• Parental (including paternal) leave, paid time off, and holidays.
• Achievement awards and backup care for children/adults.
• Annual short-term and/or long-term incentive compensation (performance-dependent).
• Relocation assistance available.

Pay

The salary range for this role is $86,800 – $165,200 USD. The final offer considers role, function, responsibilities, work experience, location, education/training, and key skills.