Thermal CFD Engineer (Battery)

Job Description

Experience: 5 to 8 years

Qualification: Master's degree in Thermal Engineering, Mechanical Engineering, Automobile Engineering, Heat Power Engineering.

Roles & Responsibilities:

• Develop 3D-CFD and conjugate heat transfer (CHT) model to predict thermal and electrical behavior of cell, stacks, pack, battery junction boxes / battery disconnect unit and other power electronic component of battery system under normal operation and abuse scenario.

• Conduct battery thermal CFD analysis at cell, module, and pack levels to support early design decisions, concept evaluations, and verification of battery systems and thermal management strategies.

• Develop 3D Conjugate Heat Transfer (CHT) CFD models using ANSA / 3D CAD in STAR-CCM+.

• Execute 3D-CFD simulations, including setup, solving, and advanced post-processing, leveraging Python scripting within STAR-CCM+.

• Perform test-to-simulation correlation and validation studies to ensure model accuracy, robustness, and predictive capability.

• Effectively communicate finding of simulation to global counterpart / project teams using appropriate technical documentation and presentation media.

• Collaborate closely with global counterpart to align on simulation scope, methodologies, assumptions, and result interpretations.

• Ensure strict adherence to simulation quality standards, best practices, and thorough documentation of methodologies, assumptions, and workflows.

• Maintain and continuously improve simulation templates, methodologies, and processes for battery CFD and thermal safety analyses.

• Deliver simulation activities in line with structured product development timelines, ensuring commitments to quality, cost, and schedule are consistently met or exceeded.

Must Have:

• 5+ years of hands-on experience in thermal CFD simulation of battery systems (cell, module, pack).

• Strong proficiency in STAR-CCM+ and experience with CFD optimization tools.

• Proven experience in test-to-model correlation and validation.

• Programming experience in Python, Java, or equivalent scripting languages.

• Experience working in Linux-based distributed computing environments.

• Demonstrated capability in result plausibility assessment, bug identification, and solver

troubleshooting.

• Strong technical knowledge of battery thermal management technique, along with a strong understanding of

thermal runaway, propagation mechanisms, and related testing methodologies.

• Solid understanding of battery systems, battery thermal safety concepts, and failure modes.

•Strong fundamentals in thermodynamics, heat transfer, CFD, and numerical modeling techniques.

• Self-motivated professional with the ability to work independently as well as collaboratively in multicultural, global teams.

• Strong analytical, conceptual, and system-level thinking capabilities.

• Excellent communication and interpersonal skills, with experience working across regions, organizations, and functions.

• Willingness to support international travel when needed.

Good to Have

• Exposure to CFD automation frameworks and simulation assistants.

• Exposure to program management tools such as Jira and Kanban boards

• Working knowledge of CAD tools such as CATIA, NX, and Space Claim.

• Experience in electro-thermal coupling (electrical + thermal simulations).

• Understanding of cell electrochemistry, aging behavior, and electrical arcing phenomena.

• Familiarity with battery safety regulations and standards, such as ECE R100 and GB 38031-2025.

• Experience in passenger vehicle programs with OEMs.

• Business-level German proficiency (minimum B1 level) is an advantage.