Thermal Systems Engineer – Vehicle & Battery

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”