Thermal Systems Engineer

Thermal Systems Engineer – Solid Rocket Motor & Energetic Operations

Location:

Bloomington, Indiana

Reports To:

Director of Engineering

Employment:
Full-time

Function:
Engineering

Travel:
As required

Clearance:
Secret Clearance (or ability to obtain; US Citizenship required)

Prometheus Energetics is an independent U.S.

-based merchant supplier of solid rocket motors and warheads. A joint venture between Kratos Defense & Security Solutions and Rafael Advanced Defense Systems, Prometheus combines U.S. industrial speed and credibility with decades of combat‑proven designs, manufacturing know‑how, and technical training to deliver field‑ready products at scale.

Prometheus Energetics is seeking an experienced Thermal Systems Engineer / Senior Thermal Systems Engineer to own the design, modeling, testing, and lifecycle integration of Thermal Protection Systems (TPS), internal case insulation, and ablative nozzle components. Reporting directly to the Director of Engineering, this role serves as a primary technical authority driving TPS development from initial concept and material characterization through motor qualification and high‑rate production.

Solid Rocket Motor (SRM) interiors demand extreme thermal protection solutions capable of withstanding hypergolic/corrosive combustion environments, rapid thermal transients, particle erosion, and alumina slag impingement. The ideal candidate brings 4 to 10 years of hands‑on aerothermal, propulsion, or high‑temperature materials engineering experience, combining strong computational modeling skills with practical experience in hot‑fire analysis, subscale testing, and factory floor integration.

• Lead the design, sizing, and qualification of thermal protection systems for solid rocket motor assemblies, including internal case insulation, elastomeric liners, nozzle ablatives, igniter insulation, and flame barriers.
• Evaluate and select high‑temperature material systems: elastomeric compounds (EPDM, N , silicone‑based rubbers), carbon‑phenolic, silica‑phenolic, carbon‑carbon composites, bulk graphite, and ceramic/silica insulation.
• Define mechanical, adhesive, and chemical compatibility requirements for TPS integration into composite and metallic motor cases, ensuring structural integrity across cure cycles, storage, and operational temperature extremes.
• Evaluate material response phenomena—including thermochemical recession, pyrolysis gas generation, char formation, oxidation, and heat soak—to maintain motor case structural margins throughout burn and post‑burn phases.
• Support scalable manufacturing processes (e.g., tape wrapping, compression molding, hand layup, mandrel winding, and automated insulation placement) to transition designs from prototype to high‑rate production.

• Develop and maintain 1D, 2D, and 3D transient thermal and ablative response models using industry‑standard software (e.g., Thermal Desktop, SINDA/FLUINT, ANSYS Thermal, Abaqus, FIAT/CMA, or equivalent solvers).
• Translate internal ballistic environments, gas chemistry, convective heat transfer coefficients, radiative flux, and slag/particle impingement profiles into robust thermal analysis boundary conditions.
• Conduct trade studies and design optimization to balance TPS mass, thermal margin, structural integrity, and manufacturability.
• Perform sensitivity analyses and model uncertainty assessments to establish reliable flight and ground test design envelopes.
• Provide thermal boundary conditions and temperature distribution fields to structural analysts for coupled thermal‑mechanical stress evaluations of motor cases, grains, and nozzles.

• Plan, execute, and evaluate subscale screening and material characterization tests (e.g., oxy‑acetylene torch, radiant lamp, furnace, and arc‑jet testing).
• Collaborate with test facility personnel to define test objectives, instrumentation layout (thermocouples, heat flux sensors, ablation gauges), and data acquisition requirements for static fires and subscale evaluations.
• Perform detailed post‑test evaluations on fired…