Senior Thermofluids Analyst

Rocket Lab is an end-to-end space company delivering responsive launch services, complete spacecraft design and manufacturing, payloads, satellite components, and more – all with the goal of opening access to space. The rockets and satellites we build and launch enable some of the most ambitious and vital space missions globally, supporting scientific exploration, Earth observation, and missions to combat climate change, national security, and exciting new technology demonstrations. Our Electron rocket has become the second most frequently launched U.S. rocket annually and has delivered more than 230 satellites to orbit, while we work to develop Neutron, our upcoming medium‑lift, reusable launch vehicle for larger constellation deployment. Our Space Systems business designs and builds our extensive line of satellites, payloads, and their components, including spacecraft selected to support NASA missions to the Moon and Mars and components used on the James Webb Space Telescope. While other companies talk about it, we do it! Neutron Rocket Lab’s Neutron team is responsible for bringing our new large rocket Neutron and its launch and test sites to life. From designing and testing Neutron’s structures and components, to firing up its new Archimedes engines, to setting up Neutron’s launch pads and test sites across the United States, joining the Neutron team is an opportunity to help launch a new large rocket for the very first time. Senior Thermofluids Analyst Rocket Lab’s integrated analysis team contributes to the operation and development of Neutron & Electron by using modelling and simulation to solve challenging problems involving dynamics, fluid flow, and thermodynamics. Whether it is using CFD simulations, writing code to model flow physics, or applying data analysis on flight measurements to understand & improve vehicle performance, analysis is critical to guide changes and develop the capability of our launch vehicles. As a Thermofluids Analyst II in Rocket Lab’s Thermofluids Analysis team you will contribute to the analysis, design validation, and improvements of Rocket Lab’s launch vehicles. Day to day, you will be expected to conduct concept development, perform trade studies, run simulations, and evaluate performance around Neutron’s pressurisation, propellant management, and reaction control systems. You will be responsible for evaluating system sizing, propellant depletion, slosh, propellant loading & conditioning, and CONOPS across all flight phases (Ascent, Descent, On‑Orbit). Join a driven team that’s tackling challenging projects, delivering on exciting missions, and making an impact on the future of space! What you'll get to do: Perform, validate, and document CFD analyses of launch vehicle fluid systems (compressible/incompressible flow, two-phase, aerodynamics, choked flow) Conduct heat transfer simulations including integrated thermal analyses (ITAs), component thermal analyses, aeroheating thermal response, and TPS specification Perform thermofluid analyses of launch vehicle systems including model development, numerical analysis, material selection, and performance optimisation studies Collaborate with design and test engineers to iterate design concepts, determine test requirements, and demonstrate positive margins Process and interpret ground test and flight data to verify MPE bounds, detect anomalies, resolve sensor issues, and determine root causes using physical principles Conduct peer reviews, document methodologies, and produce test levels (Acceptance, Proto‑qualification, Qualification) using approved margining approaches Support subsystem testing through test‑analysis correlation, pre/post‑test reports, and standardisation of analysis procedures per industry best practice Develop propellant dynamics models (temperature, gas rejection, control strategies) and contribute to automation of test and flight data review processes Qualifications: A degree in Mechanical, Aerospace Engineering or similar field 5+ years industry experience, ideally from the Aerospace, Automotive or Marine industries Strong understanding of physical principles (heat transfer, electronics, internal flow, aerodynamics, etc.) Fluid engineering experience around pressure loss, valves and sensors Demonstrated experience with one or more industry standard CFD packages: Fluent, CFX, STAR-CCM+ Experience in Python and associated scientific packages: numpy, pandas, scipy, matplotlib Demonstrated thermal modelling of components, networks and lump masses Experience with experimental test methods, sensor selection and data post‑processing/ interpretation (thermocouples, pressure transducers, accelerometers, strain gauges, microphones, etc.) The ability to work to deadlines within a high‑pressure environment Proven communication skills and the ability to build strong working relationships with colleagues and engineering professionals Nice‑to‑have Qualifications: Experience with dynamic thermofluid systems: Propellant Dynamics (slosh, flow instabilities, Pogo) Propellant level sensing and control strategies Pumps, pressurisation systems and cryogenics experience Thermodynamics of 2‑phase, cryogenics or refrigeration systems Compressible gas modelling of pressure vessels, pressurisation systems and piping Knowledge around space thermal environments and modelling for both orbital and ascent environments Thermal protection system design, specification and implementation Knowledge of HVAC system design and/or analysis Experience with one or more industry standard thermal modelling packages: Thermal Desktop, THERMICA, NX SST Familiarity using SolidWorks CAD and PDM packages (or comparable industry standard packages) with emphasis on model interrogation and defeaturing for subsequent analyses Experience in Python package development and modelling (git, CI, deployment) Familiarity with industry standards (e.g. MIL-STD-1540, GSFC-STD-7000, ECSS-E-HB-32, NASA-STD-5001) What to expect We’re on a mission to unlock the potential of space to improve life on Earth, but that’s not an easy task. It takes hard work, determination, relentless innovation, teamwork, grit, and an unwavering commitment to achieving what others often deem impossible. Our people out‑think, out‑work, and out‑pace. We pride ourselves on having each other’s backs, checking our egos at the door, and rolling up our sleeves on all tasks big and small. We thrive under pressure, work to tight deadlines, and our focus is always on how we can deliver, rather than dwelling on the challenges that stand in the way. Rocket Lab provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state, or local laws. 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