Thermal Systems Design Engineer

Job Title: Thermal Systems Design Engineer 

Job Summary:

We are seeking a skilled Thermal Systems Design Engineer (Mid-Level) to lead the design, analysis, and validation of thermal systems across diverse applications such as energy systems, automotive, HVAC, aerospace, electronics cooling, or process industries. The ideal candidate has hands-on experience in thermal-fluid system design, thermal simulation, and cross-functional collaboration to deliver reliable and efficient systems in compliance with performance and safety standards.

Key Responsibilities:

Thermal System Design & Optimization:

• Design thermal systems including heat exchangers, cooling loops, insulation, ventilation, and temperature control systems.

• Perform heat transfer and fluid flow calculations to determine thermal loads, temperature gradients, pressure drops, and material compatibility.

• Lead component sizing and system-level thermal layout, integrating thermal performance with mechanical and electrical interfaces.

Modeling & Simulation:

• Develop and validate analytical and numerical models (steady-state and transient) using software such as ANSYS Fluent, COMSOL, or SolidWorks Flow Simulation.

• Use MATLAB, Python, or Excel for parametric studies and thermal optimization.

Project Execution & Coordination:

• Collaborate with product development, controls, electrical, and mechanical teams to integrate thermal solutions into broader systems.

• Support design reviews, DFMEAs, risk assessments, and safety compliance activities.

• Interface with suppliers to evaluate thermal equipment performance and specifications.

Testing & Validation:

• Define and support thermal test plans including lab setup, sensor selection, and data acquisition.

• Analyze test results and refine simulation models or system design accordingly.

Documentation & Reporting:

• Prepare technical design reports, system specifications, and thermal performance summaries for internal and customer review.

• Maintain version-controlled documentation and support compliance with industry standards (e.g., ASME, API, ISO, SAE).

Key Focus Areas:

• End-to-end thermal system design

• Thermal-fluid modeling and optimization

• Design integration and technical documentation

• Prototype testing and cross-functional collaboration

Qualifications and Skills:

Education:

• Bachelor’s Degree in Mechanical Engineering, Thermal Sciences, Aerospace Engineering, or related field

• Master’s Degree is a plus

Certifications:

• Thermal simulation or CFD training certification preferred (e.g., ANSYS, COMSOL)

• Six Sigma or Design for Reliability (DfR) exposure is beneficial

Experience:

• 3–6 years of experience in thermal design, preferably in industries such as automotive, aerospace, power generation, or electronics cooling

• Experience with cooling system design, heat exchanger selection, or thermal interface material evaluation

Technical Skills:

• Proficiency in CAD tools (e.g., SolidWorks, Creo) and thermal simulation software

• Strong foundation in thermodynamics, conduction, convection, radiation, and phase-change systems

• Familiarity with sensors, data loggers, and thermal instrumentation

Soft Skills:

• Strong problem-solving and analytical thinking

• Excellent teamwork, written communication, and technical reporting skills

• Ability to manage multiple tasks and support junior team members