We are looking for an experienced thermal engineer to play a central role in the architecture, design, and validation of Generac's clean energy products, with a strong emphasis on innovative thermal solutions across power electronics and energy storage systems.
Roles and Responsibilities
- Architect, design, model, and validate thermal solutions for Energy Storage Systems (ESS) and power electronics
- Build CFD models and instrumented thermal test vehicles to validate designs against simulation
- Create thermal solutions that balance performance, form, and function across the product portfolio
- Optimize designs for thermal performance, DFM/DFA, acoustics, size, reliability, and cost
- Provide clear, actionable thermal design guidance to cross-functional engineering teams
- Size and select components for passive, forced-air, liquid, and two-phase thermal solutions
- Manage thermal supplier relationships, supporting component selection, validation, and integration
- Partner with validation and reliability teams to define thermal test parameters and acceptance criteria
- Collaborate with software and firmware teams to establish thermal policies for control algorithms
Minimum Qualifications
- Bachelor's degree in mechanical engineering or a related field
- Minimum 7 years of hands-on experience in thermal design and electronics cooling
- Willingness to travel up to 30%, including international travel
Knowledge, Skills, and Abilities
- Expert-level knowledge of heat transfer, thermodynamics, and fluid mechanics
- Expertise modeling passive cooling, forced-air, liquid cooling, two-phase systems, battery thermal behavior, and solar radiation
- Proficiency sizing and selecting fans, radiators, heat sinks, heat pipes, and related components
- Experience with instrumentation and data acquisition methods for thermal validation
- Expert proficiency in Ansys, Flotherm, Star-CCM+, or a comparable CFD package
Preferred Qualifications
- Master's degree in mechanical engineering with a specialization in heat transfer
- Demonstrated record of bringing thermally complex products from development into volume production
- Experience with thermal solutions for outdoor NEMA/IP-rated products
- Background in validation testing, product reliability, and failure analysis
- Proficiency with 3D CAD tools (Creo or SolidWorks preferred)
- Experience designing thermal solutions specifically for battery energy storage systems
- Familiarity with battery pack failure modes, including thermal runaway, outgassing, and propagation
- Working knowledge of UL 9540A regulatory requirements and associated testing
- Excellent written and verbal communication skills
