Thermal Systems Engineer – Vehicle & Battery

1. Simulation & Analysis (50%)

• Perform CFD-based thermal simulations using ANSYS Fluent / Star-CCM+ (mandatory).
• Battery pack thermal analysis at cell-level and module-level, including steady-state and transient cases.
• Thermal simulation of inverter and motor cooling systems.
• Under-hood and under-body airflow and thermal management studies.
• Analyze Joule heating and electrical losses in:
• Busbars, tabs, connectors
• High-current transient operating conditions
• Support thermal runaway mitigation, venting, and safety studies (good to have).
• Prepare simulation reports with clear design recommendations.

2. Design & Packaging (30%)

• Design and optimize cooling plates, ducts, and flow paths.
• Perform fan and pump sizing based on thermal and hydraulic requirements.
• Package thermal systems at the vehicle level, considering space, manufacturability, and serviceability.
• Work closely with CAD teams using SolidWorks / CATIA / NX to implement thermal solutions.
• Support design trade-offs between performance, cost, weight, and packaging constraints.

3. Execution & Validation (20%)

• Define and support sensor placement (NTCs, RTDs, thermocouples) for validation.
• Correlate CFD results with vehicle, dyno, and bench test data.
• Coordinate with vendors for radiators, pumps, hoses, and thermal components.
• Support vehicle testing, dyno testing, and on-road validation activities.
• Troubleshoot thermal issues observed during testing and production trials.

Required Qualifications

• Bachelor’s or Master’s degree in Mechanical, Automotive, Electrical, or Thermal Engineering
• 3–7 years of relevant industry experience
• Background in EVs, automotive systems, or power electronics
• Direct involvement in at least one running vehicle program or battery pack

• Strong expertise in ANSYS Fluent or Star-CCM+ (non-negotiable)
• Working experience with Icepak (strong plus)
• Practical understanding of:
• Battery thermal management systems
• Motor and inverter cooling
• Vehicle-level airflow and heat rejection
• CAD experience using SolidWorks / CATIA / NX
• Basic proficiency in MATLAB for data analysis and post-processing
• Familiarity with thermal testing, validation, and correlation methods

• Ability to work effectively with incomplete or evolving data
• Strong engineering judgment beyond simulation results
• Comfortable with fast iteration cycles and startup-style execution
• Hands-on mindset with shop-floor and test-track interaction
• Clear communication with cross-functional teams (design, testing, vendors)
• Problem-solving approach focused on real-world performance, not just “CFD says OK”