Thermal Systems Engineer – Vehicle & Battery
Bengaluru, IndiaFull-timeMid · 3-7 years
About this role
Job Purpose (Significance of the Role & Objectives)
We are looking for a Thermal Systems Engineer – Vehicle & Battery with strong experience in CFD-based thermal analysis for EV battery packs and powertrain systems. The role involves end-to-end ownership of thermal simulations, cooling system design, vehicle-level integration, and correlation with test data. The ideal candidate has hands-on experience working on at least one running vehicle or battery pack program.
Key Responsibilities and Deliverables
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.
Desired Qualifications: Required Qualifications, Knowledge, and Experience
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
Knowledge and Experience
- 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
Key Competencies
- 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”