In high-stress aviation environments, maintaining optimal pilot performance is critical for flight safety. This study investigates the relationship between cognitive workload, stress, and facial thermal responses during simulated Airbus A320 takeoff procedures. Utilizing a multimodal approach, facial thermography, heart rate monitoring, and EEG-derived workload measures were recorded from ten participants—five with and five without prior simulation experience—while they navigated 12 distinct flight scenarios comprising both standard and engine failure conditions. The experimental design featured two rounds of simulation tasks interleaved with rest periods to capture both cooling (during task performance and stress) and warming (rest and recovery) phases. Results revealed that elevated cognitive workload induced significant cooling across the nose, forehead, and cheeks, with the nasal region exhibiting the most rapid and pronounced temperature decline. These thermal changes were synchronized with increases in heart rate and subjective workload ratings, thereby validating the use of facial thermography as an objective, real-time indicator of stress. Additionally, preliminary analyses suggest that individual differences, such as prior simulation experience, moderate the magnitude of these physiological responses. The findings underscore the potential of integrating facial thermal imaging into cockpit monitoring systems as an early warning mechanism for cognitive overload. Future work should focus on refining critical temperature thresholds and exploring real-world applicability to further enhance pilot training and operational safety.