{"id":2985219,"url":"https://alion.io/job/castelion-senior-aerothermal-cfd-engineer","title":"Senior Aerothermal & CFD Engineer","company":{"id":1795053,"name":"Castelion","domain":"castelion.com","url":"https://alion.io/company/castelion","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Greenhouse","truth_index":null},"role":"Aerospace","role_family":"Aerospace","seniority":"senior","employment_type":null,"work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":[],"countries":[],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":119000,"max_usd":214000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":265},"experience_years_min":5,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"MATLAB","optional":false},{"name":"Python","optional":false},{"name":"STAR-CCM+","optional":false}],"status":"live","first_seen_at":"2026-09-15T00:53:29Z","employer_posted_date":"2026-09-17","last_verified_at":"2026-10-31T07:51:21Z","board_verified":true,"closed_at":null,"days_open":46,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":46},"description":"Why Castelion, Why Now \nCastelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability. \nThis is a rare opportunity to join at an early stage, where you'll have significant ownership, collaborate with exceptional teammates, and make a direct, measurable impact on our mission and the future of the company - regardless of your function. \nSenior Aerothermal & CFD Engineer \nWe are seeking a Senior Aerothermal & CFD Engineer to develop computational fluid dynamics (CFD) and aerothermal solutions for Castelion's long-range hypersonic strike vehicles. This role is critical to predicting aerodynamic loads, pressure distributions, and thermal environments that drive vehicle design. You will work hands-on with multidisciplinary engineering teams to analyze, model, and validate complex fluid dynamic and aerothermal phenomena from concept through flight testin a fast-paced, hardware-driven environment. \nResponsibilities\nPerform computational fluid dynamics (CFD) analyses of hypersonic flight vehicles across a wide range of Mach numbers and flight conditions\nPredict aerodynamic loads, pressure distributions, and surface heating environments for flight vehicle structures and thermal protection system\nAnalyze shock interactions, boundary layer behavior, flow separation, and high-temperature flow phenomena\nDevelop high-fidelity CFD models to support propulsion integration, control surface design, thermal protection systems, and vehicle configuration trades\nWork closely with flight sciences, TPS, structures, propulsion, GNC, and manufacturing teams to ensure seamless integration of aerodynamic and thermal analyses\nCorrelate CFD predictions with wind tunnel, arc-jet, ground test, and flight test data to improve model fidelity\nDevelop efficient meshing strategies, solver methodologies, and automated CFD workflows\nSupport design reviews by providing aerodynamic and aerothermal analyses that inform key technical decisions\nMentor junior engineers and contribute to best practices in CFD and aerothermal analysis\nPartner closely with program leadership to make technical trades aligned with mission success\nBasic Qualifications\nBachelor's, Master's, or PhD in Aerospace Engineering, Mechanical Engineering, or related field \n5+ years of experience performing CFD and aerothermal analysis for aerospace or defense applications\nStrong background in compressible fluid dynamics, hypersonic aerodynamics, and heat transfer\nExperience using CFD tools such as STAR-CCM+, Fluent, FUN3D, CFD++, US3D, or equivalent\nExperience with turbulence modeling, shock-boundary layer interactions, and high-temperature flow physics\nFamiliarity with aerothermal heating prediction and thermal protection system design support\nExperience generating aerodynamic load and heating environments for structural and thermal analyses\nExperience with scripting and automation using Python, MATLAB, or equivalent\nFamiliarity with wind tunnel testing, arc-jet testing, or flight test correlation\nStrong problem-solving mindset, thriving in a fast-paced, hardware-rich, high flight cadence environment\nCastelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details. \nOther Duties \nPlease note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice. \nAdditional Eligibility Requirements \nThis position may require access to classified information or restricted U.S. Government sites, systems, or information, as determined by the Company and/or applicable U.S. Government requirements. If the position is so designated, your employment in the role may be contingent upon your ability to obtain and maintain the required U.S. Government security clearance or other government authorization, and to satisfy any citizenship or other eligibility requirements imposed by applicable law, regulation, executive order, or government contract requirements. You will be notified if and when such requirements apply. \nAffirmative Action/EEO Statement \nCastelion is an Equal Opportunity Employer. We are committed to providing equal employment opportunities to all applicants and employees without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, genetic information, protected veteran status, or any other characteristic protected by applicable federal, state, or local law. \nCastelion is committed to providing reasonable accommodations to qualified individuals with disabilities throughout the application and hiring process. If you require a reasonable accommodation to complete an application, participate in the interview process, or otherwise participate in the hiring process, please contact . Requests for accommodation will be considered on an individual basis and handled in accordance with applicable law. \nCastelion is committed to fostering a workplace where employment decisions are based on qualifications, business needs, and the ability to perform the essential functions of the role, with or without reasonable accommodation. \nEAR/ITAR Requirements \nThis position requires access to export-controlled information, and as such, employment (or hiring of a contractor) is contingent upon the candidate’s ability to access all applicable export-controlled information without additional export licensing being required by the Bureau of Industry and Security and/or the Directorate of Defense Trade Controls.","description_format":"text","description_chars":5831,"description_truncated":false,"requirements":{"experience_years_min":5,"management_years_min":null,"team_size_min":null,"manages_managers":false,"education":{"level":"bachelor","optional":false},"security_clearance":true,"languages":[]},"benefits":[],"hiring_locations":[{"name":"United States","iso":"US","kind":"country"}],"hiring_excludes":[],"relocation_offered":false,"industries":["Missiles","Defense Manufacturing"],"lifecycle":[{"event":"open","at":"2026-10-21T08:14:48Z"}],"visa":[],"liveness":{"score":36,"band":"fade","label":"Fading","p_open":1,"p_active":0.821,"p_room":0.44,"age_days":46,"expected_fill_days":46,"reasons":["conf:1","velocity","win:tail","crowd:brand"],"computed_at":"2026-10-31T05:58:55Z"},"pay":null,"html_url":"https://alion.io/job/castelion-senior-aerothermal-cfd-engineer","json_url":"https://alion.io/job/castelion-senior-aerothermal-cfd-engineer.json","meta":{"generated_at":"2026-10-31T08:28:43Z","cache_seconds":300,"methodology":"https://alion.io/methodology","terms":"https://alion.io/terms","contact":"https://alion.io/contact","api":"https://alion.io/developers","about":"Alion is a live layer of people, companies and AI agents: who they are, whether they are real and active right now, what they do and how to work with them, readable by people and by agents and paid per call.","catalog":"https://alion.io/catalog.json","usage":{"tier":"crawler_verified","counted_by":"address","units_charged":1,"used_today":12632,"day_limit":null,"remaining_today":null,"minute_limit":300,"resets_at":"2026-11-01T00:00:00Z"}},"offers":[{"id":"company.slices","title":"One company in depth, by slice","status":"live","price":{"credits":0.02,"usd":0.002,"plus_per_slice":{"credits":0.05,"usd":0.005}},"unit":"per company, plus each slice with data","note":"the employer in depth","call":{"mcp_tool":"get_company","arguments":{"id":1795053},"rest":"https://alion.io/mcp/rest/get_company?id=1795053"},"human":"https://alion.io/catalog?offer=company.slices&for=job%2Fcastelion-senior-aerothermal-cfd-engineer"},{"id":"market.stats","title":"A market slice: pay, demand and time to fill","status":"live","price":{"credits":1,"usd":0.1},"unit":"per slice","note":"pay, demand and time to fill for this role and place","call":{"mcp_tool":"market_stats"},"human":"https://alion.io/catalog?offer=market.stats&for=job%2Fcastelion-senior-aerothermal-cfd-engineer"},{"id":"job.search","title":"Open jobs by role, technology, place, pay and visa","status":"live","price":{"credits":0.02,"usd":0.002},"unit":"per posting in a list","note":"similar open postings","call":{"mcp_tool":"search_jobs"},"human":"https://alion.io/catalog?offer=job.search&for=job%2Fcastelion-senior-aerothermal-cfd-engineer"},{"id":"company.verify","title":"Is this company real and active right now","status":"pilot","price":null,"unit":"per company","request":{"url":"https://alion.io/catalog/request","method":"POST","body":"{\"offer\": \"company.verify\", \"for\": \"job/castelion-senior-aerothermal-cfd-engineer\", \"note\": \"what you need it for\"}"},"human":"https://alion.io/catalog?offer=company.verify&for=job%2Fcastelion-senior-aerothermal-cfd-engineer"}],"agent":{"mcp":"https://alion.io/mcp/jobs","mcp_open":"https://alion.io/mcp/open","next":[{"tool":"get_job","arguments":{"id":2985219}},{"tool":"search_jobs","arguments":{"company":"castelion.com","detail":"compact"}},{"tool":"match_people","arguments":{"job_id":2985219},"note":"people open to offers who fit this vacancy"}],"note":"The same data through MCP tools: https://alion.io/mcp/open needs no sign-in (compact searches, postings, people); https://alion.io/mcp with an Alion account has everything. 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