The Senior Thermal Systems Engineer – Turbo Integration is a technical leader responsible for developing and validating advanced thermal management strategies for turbocharger systems in combustion and hybrid-electric powertrains. This role leads the thermal design process from concept through production, applying simulation, testing, and system-level integration to manage heat transfer, ensure component durability, and optimize thermal packaging in complex underhood environments.
Lead end-to-end thermal integration of turbocharger systems within engine and hybrid platforms, including exhaust manifolds, aftertreatment, intercoolers, and coolant/oil circuits.
Drive high-fidelity thermal simulations (steady-state, transient, conjugate heat transfer) and correlate with physical testing data.
Define and validate thermal protection strategies (heat shielding, thermal barriers, insulation, and active cooling).
Own thermal design reviews, DFMEA, and thermal validation plans (DVP&R) for turbo-integrated systems.
Serve as the thermal interface with cross-functional teams (design, validation, engine calibration, vehicle integration, and suppliers).
Lead thermal failure analysis and resolution of durability or heat-related issues during development or production.
Guide junior engineers in thermal modeling best practices and system-level thinking.
Advanced thermal analysis and design for turbocharger and engine system integration
Heat shielding and protection strategies in constrained engine bay packaging
Simulation-test correlation and risk mitigation
Cross-disciplinary leadership on turbo thermal performance
Hybrid and electrified system thermal integration (as applicable)
Bachelor’s degree in Mechanical, Thermal, or Automotive Engineering (Master’s or PhD preferred)
7+ years of experience in thermal systems engineering, including turbochargers, engine cooling, exhaust systems, or hybrid powertrains
Proven ownership of thermal integration in a production vehicle program
Expertise in CFD and thermal modeling tools (e.g., ANSYS Fluent, GT-SUITE, FloTHERM, Thermal Desktop)
Strong background in heat transfer fundamentals: conduction, convection, radiation, and transient analysis
Knowledge of engine architecture, turbocharger technology, and underhood thermal management
Skilled in interpreting thermal test data, sensor layout, and thermal instrumentation planning
Technical leadership and mentoring capabilities
Excellent communication and presentation skills
Ability to drive decisions across departments and manage thermal trade-offs in a fast-paced environment