Senior Mechanical Engineer, Thermal Protection Systems

Canopy Aerospace & Defense

• $130K — $180K *
Aerospace & Defense
Less than 5 years of experience
Job Overview by Ladders

Qualifications

  • 4+ years of experience designing TPS components/assemblies qualified through flight or high-enthalpy testing.
  • Knowledge of TPS materials like thermal blankets, ablative carbon composites, and ceramics.
  • Experience in full lifecycle design from concept to manufacturing, including CAD modeling and GD&T.
  • Strong foundation in structural mechanics, materials science, thermodynamics, and heat transfer.
  • Track record of delivering hardware on accelerated schedules using creative engineering solutions.
  • Excellent communication skills for conveying complex concepts to interdisciplinary teams.
  • Eligibility for U.S. Security Clearance: Active Secret clearance or ability to obtain.

Responsibilities

  • Execute end-to-end ownership of TPS components, from requirements through delivery.
  • Drive material trade studies balancing thermal survivability and structural integrity.
  • Collaborate with aerothermal, design, and test teams to create robust mechanical designs.
  • Develop CAD models and drawings, ensuring manufacturing meets specifications.
  • Support testing campaigns such as arc-jet and iterate designs based on data.
  • Act as a subject matter expert in TPS technologies and innovations.
  • Lead technical sections of proposals to enhance organizational capabilities.

Benefits

  • Company paid medical, dental, and vision insurance.
  • 401K company match with eligibility requirements.
  • Paid sick leave and vacation.
  • Paid holidays and discretionary bonuses.
Full Job Description
Key Responsibilities

  • Execute end-to-end ownership of TPS components and subassemblies, from initial requirements definition through final hardware delivery.
  • Own and drive material trade studies that balance thermal survivability, structural integrity, and manufacturing realities for hypersonic regimes.
  • Collaborate cross-functionally with aerothermal, design, materials, and test groups to translate heat flux and aero loads into robust mechanical designs.
  • Develop detailed CAD, drawings, ICD's, interface directly with the manufacturing floor, and ensure parts are built to spec.
  • Support rigorous testing campaigns such as arc-jet, rapidly perform raw data reduction, and draw actionable conclusions to iterate designs based on empirical data.
  • Serve as the resident SME in the TPS space, maintaining robust knowledge of current state-of-the-art and next-generation technologies.
  • Lead technical sections of proposals and new products that enhance the organization's technical capabilities and support strategic defense growth objectives.


Required Qualifications

  • 4+ years of direct, verifiable experience designing and owning TPS components or assemblies qualified through flight or high-enthalpy testing (e.g., arc-jet facilities such as NASA Ames, AEDC).
  • Comprehensive knowledge of TPS materials and architectures, including thermal blankets, ablative carbon composites, rigid ceramics, and cryogenic insulation for re-entry and hypersonic environments.
  • Full lifecycle design experience taking hardware from concept through manufacturing, including 3D CAD modeling, drawing release, and GD&T application.
  • Strong technical foundation in structural mechanics, materials science, thermodynamics, heat transfer, and ablation mechanics.
  • Demonstrated track record of delivering hardware on accelerated schedules through pragmatic, creative engineering solutions.
  • Strong interdisciplinary communication skills, with the ability to clearly convey complex technical concepts across cross-functional teams.
  • U.S. Security Clearance Eligibility: Active Secret clearance (or higher), or the ability to obtain and maintain one, including meeting U.S. government background and export-control requirements


Preferred Qualifications

  • Graduate degree in Mechanical Engineering, Aerospace Engineering, Materials Science, or a related technical field.
  • Flight Heritage: Direct ownership of a TPS system that successfully operated and survived in a flight environment.
  • Systems Experience: Direct experience working on the design, test, or integration of re-entry systems, launch vehicles, or hypersonic platforms.
  • Programmatic Acumen: Experience planning and estimating complex projects, constructing bids and Basis of Estimates (BOEs), and developing technical schedules that were successfully executed.
  • Business Development: Proven track record of writing and winning IRAD and/or CRAD proposals.
  • Customer Facing: Experience interfacing directly with government (DoW, NASA) and commercial customers to define requirements and deliver technical updates.
  • Supply Chain Command: Experience and high comfort level interfacing with, auditing, and managing suppliers specifically within the TPS and advanced materials space.
  • Strong background operating within the defense sector.
  • Familiarity with space and defense standards such as but not limited to SMS-S-016, MIL-STD-810, NASA-GSFC-7000 series or other industry equivalent standards for design, analysis, and testing of defense articles.


Additional Requirements

  • Ability to work in office, lab, and manufacturing environments with occasional exposure to noise, dust, and temperature variations.
  • Must be able to lift and carry up to 35 lb and perform tasks involving standing, walking, bending, and manual assembly.
  • Visual acuity required for reading technical drawings, inspecting components, and operating precision instruments.
  • Occasional travel to customer or test sites, including outdoor or industrial settings, with adherence to company and OSHA safety protocols.
  • Must have professional working proficiency reading, writing, and speaking English.


Job Details

Salary Range: $130,000 - $180,000

FLSA Classification: Salary Exempt
Type: Full Time
Base Location: Littleton, CO
Travel: Up to 25%

Your actual level and base salary will be determined on a case-by-case basis and may vary based on the following considerations: job-related knowledge and skills, education, and experience.

Total compensation will also include a comprehensive set of benefits including but not limited to: Company paid employee medical, dental and vision insurance. 401K company match (eligibility required), paid sick leave, paid vacation, paid holidays and discretionary bonuses.

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