Senior Aerospace Engineer - Aerothermal & Hypersonics

Mach Industries Senior Aerospace Engineer – Aerothermal & Hypersonics

Mach Industries is seeking a Senior Aerospace Engineer – Aerothermal & Hypersonics to own high-speed aerodynamic and aerothermal design for next-generation hypersonic and atmospheric entry systems. This role is for an engineer with 5–7+ years of experience who has taken complex aerospace work from concept through design, analysis, test, and implementation — and who can help stand up aerothermal and TPS test capability as the company scales.

You will lead hypersonic vehicle shaping and aero/aerothermal trades, predict aerodynamic heating and related high-temperature flight environments, and contribute to Thermal Protection System (TPS) / heat-shield evaluation in partnership with materials, structures, and Thermal Engineers. You will also support lower-speed aero work in conjunction with other aerodynamicists when programs require it.

• High-speed aero and aerothermal design:
  Lead or co-own aerodynamic and aerothermal design activities for hypersonic and atmospheric entry vehicles — vehicle shaping, performance, stability, and thermal environment definition — and support lower-speed aero work in conjunction with other aerodynamicists when the program requires it.
• Aerothermal environments:
  Predict and analyze aerodynamic heating environments (convective and radiative where relevant), including engineering (first-order / closed-form) heating methods and higher-fidelity aerothermal analysis as needed to support vehicle, TPS, and structural design.
• TPS / heat-shield contribution:
  Develop and evaluate Thermal Protection System concepts, materials, architectures, and margins for hypersonic flight and atmospheric entry vehicles — including material selection support and thermal performance assessment — in close partnership with materials and structures.
• Trajectory-coupled environments:
  Perform or closely support entry, descent, and re-entry (and hypersonic mission) trajectory-informed aerothermal environment prediction and vehicle performance assessments.
• Multidisciplinary integration:
  Partner with structures, Thermal Engineers, propulsion, GNC, and systems engineering to close vehicle-level trades among aero, heating, TPS mass/thickness, and mission performance.
• Analysis, trades, and documentation:
  Build and maintain engineering models, run trade studies, and document assumptions, margins, and recommendations for design reviews across the product lifecycle.
• Test and validation (stand-up + execute):
  Help establish and then support ground aerothermal/TPS test approaches and flight-test planning, execution, data analysis, and post-flight validation — including correlation of predicted environments and TPS performance to test evidence.

• Bachelor's or Master's degree in Aerospace Engineering, Mechanical Engineering, or a related field.
• 5–7+ years of professional aerospace engineering experience.
• Demonstrated experience contributing to or leading a project from initial concept through implementation (design, analysis, test, and fielding or equivalent closure).
• Demonstrated experience in hypersonic aerodynamic design — vehicle shaping, aerodynamic performance optimization, and computational or experimental analysis for high-speed flight or atmospheric entry vehicles.
• Strong working understanding of:
• Hypersonic flight and atmospheric entry environments
• Aerodynamics for high-speed vehicles, with ability to support lower-speed aero alongside aero teammates
• Aerothermal analysis and aerodynamic heating (including engineering heating methods and high-temperature gas dynamics)
• TPS materials, architectures, and thermal performance evaluation (working fluency; deep heat-shield ownership is a plus)
• Experience with CFD, aerothermal, and aerodynamic analysis tools; familiarity with several of: STAR-CCM+, FUN3D, LociCHEM, US3D, CFD++, DATCOM, OpenVSP, MATLAB, and Python.
• Experience working in fast-paced, multidisciplinary engineering environments.
• Strong analytical, documentation, and communication skills; ability to mentor and provide technical leadership appropriate to a senior IC.
• Must be a U.S. person (U.S. citizen or…