Powertrain Thermal Engineer (Modeling , Simulation, GT-Suite)

Vehicle Thermal Simulation Engineer

Location: Auburn Hills, MI

Position Overview

we are seeking a Vehicle Thermal Simulation Engineer to support the development, simulation, and optimization of vehicle thermal management systems. The engineer will perform thermal and fluid-flow simulations, analyze vehicle thermal performance, correlate simulation results with physical testing, and work closely with design and engineering teams to deliver robust thermal solutions.

Responsibilities

• Perform vehicle thermal system simulations to evaluate cooling performance, heat transfer, temperature distribution, and thermal loads.
• Develop and maintain 1D and/or 3D thermal simulation models for vehicle thermal management systems.
• Analyze thermal performance of powertrain, battery, HVAC, cooling, exhaust, and other vehicle systems .
• Conduct simulations for coolant flow, pressure drop, heat rejection, component temperatures, and thermal balance .
• Support development of EV and hybrid vehicle thermal-management systems , including battery thermal management.
• Correlate simulation results with vehicle/component test data and identify areas for model improvement.
• Perform simulation studies to support design optimization and troubleshooting of thermal systems.
• Work with design engineers to evaluate proposed hardware changes and their impact on thermal performance.
• Prepare simulation reports, technical presentations, and engineering documentation.
• Support design reviews, engineering investigations, and root-cause analysis of thermal issues.
• Collaborate with CFD, testing, controls, powertrain, battery, HVAC, and vehicle integration teams.
• Participate in development activities from concept through production release .
• Ensure simulation activities meet engineering requirements, project timing, and quality objectives.

Required Qualifications

• Bachelor's degree in Mechanical Engineering, Automotive Engineering, Aerospace Engineering, or a related engineering discipline .
• Experience with vehicle thermal management, thermal simulation, CFD, or CAE analysis .
• Strong understanding of:
• Thermodynamics
• Heat transfer
• Fluid mechanics
• Thermal management
• Heat exchangers and cooling systems
• Experience developing and analyzing thermal simulation models .
• Ability to interpret engineering drawings, specifications, and test data.
• Strong analytical, problem-solving, and communication skills.
• Experience working in an automotive OEM or Tier-1 supplier environment is preferred.

Preferred Qualifications

• Experience with GT-SUITE / GT-POWER , Simcenter Amesim, ANSYS Fluent, STAR-CCM+, or similar CAE/thermal simulation tools.
• Experience with MATLAB/Simulink or Python for data analysis and automation.
• Experience with EV battery thermal management systems (BTMS) .
• Knowledge of vehicle HVAC, coolant circuits, radiator/condenser systems, heat pumps, and powertrain cooling .
• Experience with simulation-to-test correlation and model validation.
• Familiarity with CAN data and vehicle test measurements .
• Knowledge of automotive thermal requirements and development processes.
• Experience with DOE, optimization, sensitivity analysis, and automated simulation workflows .

Key Skills

Vehicle Thermal Simulation | Thermal Management | CFD | CAE | Heat Transfer | Thermodynamics | Fluid Mechanics | Cooling Systems | Battery Thermal Management | EV Thermal Systems | GT-SUITE | GT-POWER | ANSYS Fluent | STAR-CCM+ | Amesim | MATLAB | Simulink | Simulation Correlation | Thermal Testing | Automotive Engineering

Education

Bachelor's degree in Mechanical Engineering, Automotive Engineering, Aerospace Engineering, or related field.

Ideal Candidate

The ideal candidate will have hands-on experience in automotive thermal simulation and vehicle thermal management , with the ability to build simulation models, interpret results, correlate models with physical testing, and work with cross-functional engineering teams to resolve complex thermal-performance issues.