Powertrain Cooling Systems - Design & Release Engineer

Job Summary We are seeking an experienced Design Release Engineer (DRE) – Powertrain Cooling Systems to lead the end-to-end design, integration, validation, and release of thermal management components dedicated to power generation and propulsion units. In this role, you will own the cooling loops for internal combustion engines (ICE), turbochargers, transmission/axle oil circuits, and electric drive units (e-motors, inverters, and reduction gearboxes).

You will manage components through the full development cycle from initial concept to Start of Production (SOP)—ensuring optimal operating temperatures, durability, heat rejection, and fluid dynamics under extreme duty cycles.

Key Responsibilities 1. Component Design & Vehicle Integration

• Lead the CAD design, spatial packaging, and routing of engine/e-motor coolant jackets, mechanical and electric water pumps, thermostats, multi-way rotary valves, transmission oil coolers (TOC), engine oil coolers (EOC), and charge air coolers (CAC).
• Package heat exchangers, fluid lines, and mounting brackets within tight engine bay and drive-unit envelopes, ensuring proper clearance for engine movement, heat radiation, and chassis dynamics.
• Implement Design for Manufacturability and Assembly (DFMA) principles to facilitate efficient assembly plant installation and service access.
• Thermal Performance & Validation
• Develop and execute the Design Verification Plan and Report (DVP&R), enforcing standards for heat rejection capacity, thermal shock, pressure drop, burst pressure, fluid compatibility, and flow distribution.
• Collaborate with 1D/3D CFD and thermal simulation engineers (GT-SUITE, AMESim, Ansys Fluent) to optimize coolant flow rates, cavitation limits, and warm-up times.
• Support climate wind tunnel testing, high-altitude trail runs, hot/cold weather vehicle testing, and physical prototype evaluations.
• Lead root cause analysis (8D, 5 Whys, Fishbone) for fluid leaks, thermal degradation, pump cavitation, or overheating issues.
• Change Management & Release Execution
• Author and manage technical document releases, including Design FMEAs (DFMEA), 2D engineering drawings, 3D CAD models, material specifications (aluminum alloys, EPDM, high-temp polymers), and GD&T tolerance stacks.
• Process Change Notices (CNs/ECNs) to track engineering modifications, mass optimization initiatives, and cost-reduction proposals.
• Approve Tool Kick-Off (TKO) requests for cooling modules and cast pipes, manage Source Package releases, and issue Interim Approval Authorizations (IAAs).
• Supplier & Cross-Functional Interface
• Primary technical contact for Tier-1 powertrain cooling suppliers; manage supplier progression through APQP / PPAP milestones.
• Interface directly with Powertrain Systems Architects, Transmission Engineers, Engine Calibration Teams, Quality, Purchasing, and Assembly Operations.

Qualifications & Requirements

• Education: Bachelor’s degree in Mechanical Engineering, Automotive Engineering, Thermal/Fluids Engineering, or related field.

• Experience: 3+ years of experience as a DRE or Product Engineer specializing in powertrain cooling, heat exchangers, fluid pumps, or thermal distribution systems.

• Technical Knowledge:

• Solid understanding of thermodynamics, heat transfer, fluid mechanics, and coolant/oil lubrication dynamics.

• Knowledge of aluminum brazing, die-casting, plastic injection molding, and elastomeric seal/hose behavior.

• Proficiency in 3D CAD platforms (CATIA V5/V6 or Siemens NX) for spatial packaging and surface modeling.

• Process Mastery: Deep working knowledge of DFMEA, DVP&R, GD&T, APQP, PPAP, and OEM engineering release software (e.g., Teamcenter, Enovia).

• Languages: Business fluency in English (written and spoken).

Preferred Qualifications

• Experience with Electric Drive Unit (EDU) cooling (stator oil-cooling jackets, inverter cold plates, integrated thermal management units).
• Experience with engine calibration interactions (thermostat opening strategies, variable displacement water pump maps).

Key Competencies

• Thermal Systems Mastery: Deep technical understanding of how component-level heat transfer impacts overall powertrain efficiency, emissions, and reliability.
• Cross-Functional Collaboration: Ability to negotiate packaging space and thermal trade-offs with Powertrain, Structural, and Chassis teams.
• Analytical Problem Solver: Skilled in analyzing thermodynamic test data to identify flow restrictions, heat soak anomalies, and structural stress points.

SEGULA Technologies is a global engineering group, boosting the competitiveness of all major industrial sectors: automotive, aerospace, energy, rail, naval, life sciences, and telecoms. With a presence in more than 30 countries and 140 locations worldwide, the Group prioritizes close relationships with its clients, driven by the expertise of its 15,000 employees. As a leading engineering player putting innovation at the heart of its strategy, SEGULA Technologies manages large-scale projects, ranging from initial studies to industrialization and production. SEGULA TECHNOLOGIES is dedicated to gender balance and diversity, recognizing and recruiting talent of all backgrounds.