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”
