The Mid-Level Thermal Systems Engineer leads the design, analysis, and validation of thermal solutions for turbocharger systems and their integration into internal combustion and hybrid powertrains. This role focuses on managing heat flow and protecting surrounding components in high-temperature engine environments. The engineer applies simulation tools, test data, and system-level design principles to ensure thermal performance, durability, and packaging feasibility of the turbo system.
Perform steady-state and transient thermal simulations (1D and 3D) to assess turbo system behavior and engine bay heat exposure.
Design and specify thermal protection measures such as shielding, insulation, and optimized airflow for heat-sensitive components.
Lead thermal reviews during design, prototype, and validation stages, ensuring compliance with thermal performance targets.
Collaborate with packaging, exhaust, powertrain, and vehicle integration teams to develop thermally robust solutions.
Analyze test data from dyno and vehicle environments to validate models, refine designs, and support issue resolution.
Participate in DFMEA, DVP&R, and risk mitigation activities related to thermal behavior and failure modes.
Interface with suppliers and partners to align on thermal specifications and integration practices.
Thermal simulation and analysis of turbo-integrated systems
Design of heat protection strategies for engine and vehicle environments
Engine bay packaging optimization for heat management
Test correlation, validation, and thermal compliance reporting
Bachelor’s degree in Mechanical, Thermal, or Automotive Engineering (Master’s preferred)
3–6 years of experience in thermal systems engineering for engine, turbocharger, or powertrain applications
Proficiency with thermal simulation tools (e.g., ANSYS Icepak, GT-SUITE, FloTHERM, Thermal Desktop)
Competency in CAD platforms (CATIA, Creo, SolidWorks) and thermal model validation
Understanding of engine cooling systems, exhaust routing, and heat exchanger design
Familiarity with thermocouple data analysis, instrumentation setup, and test procedures
Strong analytical and problem-solving abilities
Effective communication and cross-functional collaboration skills
Capable of leading small projects and working independently with minimal oversight