Thermal Design and Simulation Engineer

Job Summary

• We are hiring a Thermal Engineer to lead the design, simulation, and validation of thermal systems for our next-gen eVTOL propulsion platforms. You’ll work on radiators, forced convection cooling, motor and inverter thermal analysis, and powertrain packaging, using tools like STAR-CCM or Ansys . With high power and torque densities, thermal management is critical to our system’s performance.
  
  
  

• Lead the design and analysis of thermal management systems for electric powertrains (motors, inverters, gearboxes) in eVTOL applications.
• Model and optimize radiator geometry, airflow ducting, and integration with propeller-induced or free-stream flows.
• Drive thermal design of electric motors and inverters, including winding cooling, stator housing, Fin plate and jacket cooling.
• Develop and validate complete cooling system architectures including pump sizing, plumbing layout, and pressure drops.
• Collaborate cross-functionally with mechanical, electrical, and controls teams for thermal packaging, placement, and interface design.
• Define test plans, support thermal testing, and perform simulation-to-test correlation for performance validation.
• Generate technical documentation, DVP&R, and design reports for internal and external stakeholders.
• Perform CFD simulations (forced convection, natural convection, conjugate heat transfer, radiator sizing) using STAR-CCM+
  
  
  

• Bachelor’s or Master’s degree in Mechanical, Aerospace, Thermal Engineering or related field.
• 5+ years of industry experience in thermal system design and analysis, ideally in aerospace, automotive, or high-performance EVs.
• Proficient in thermal-fluid design & simulations (CFD, CHT, radiator design) and analysis.
• Solid understanding of forced convection cooling, especially with non-uniform/ducted airstreams such as from propellers or ambient airflow.
• Proven experience in electric motor and inverter thermal design.
• Strong understanding of thermal packaging, heat exchanger performance, and power electronics cooling.
• Ability to work from concept to validation, including simulation, hardware definition, and testing.
• Familiarity with interpreting CFD results and translating into design decisions and improvements.
  
  
  

• Experience with aerospace applications, especially eVTOL, UAVs, or high-speed electric aircraft.
• Knowledge of coolant plumbing layout, hose/connector selection, and pressure-drop analysis.
• Exposure to motor cooling systems, phase change materials.
• Familiarity with Siemens Simcenter, AMESim, or other 1D thermal simulation tools.
• Experience in test bench setup, data acquisition, and thermal sensor instrumentation.
• Hands-on experience in CAD tools (CATIA, SolidWorks, etc) for mechanical design related to thermal systems.
• Experience working in cross-disciplinary teams including mechanical, controls, and integration engineering.