Thermal CFD & Heat Transfer Simulation Engineer eVTOL Propulsion Systems

5-7 Years

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Job Description

Job Summary

We are hiring a Thermal CFD & Heat Transfer Simulation Engineer to lead the design, simulation, and validation of thermal management systems for next-generation eVTOL propulsion platforms. The role involves advanced CFD and conjugate heat transfer (CHT) analysis of propulsion radiators, electric motors, inverter controllers, coolant flow networks, and integrated thermal architectures using STAR-CCM+, ANSYS Fluent, or similar tools. The engineer will work closely with propulsion, mechanical, electrical, and systems teams to optimize cooling performance, reduce thermal hotspots, and improve system reliability under aerospace operating conditions.

Key Responsibilities

Lead CFD and thermal simulation activities for propulsion radiator systems, electric motors, and inverter controllers used in eVTOL applications.
Develop 3D CFD models for airflow, coolant flow, and conjugate heat transfer using STAR-CCM+, ANSYS Fluent, or equivalent platforms.
Perform radiator sizing, fin optimization, pressure-drop analysis, and thermal performance evaluation under hover and cruise operating conditions.
Conduct motor cooling simulations including stator winding cooling, rotor thermal analysis, housing heat dissipation, and oil/air cooling strategies.
Simulate inverter and power electronics thermal behavior including busbars, IGBT/MOSFET cooling plates, and liquid-cooled cold plates.
Evaluate forced convection, natural convection, transient thermal behavior, and multiphase cooling concepts for aerospace propulsion systems.
Create detailed thermal network models and correlate CFD predictions with 1D thermal models and experimental test data.
Optimize ducting layouts, coolant routing, pump sizing, manifold designs, and thermal packaging integration.
Support thermal test planning, instrumentation setup, and simulation-to-test correlation for validation activities.
Generate technical reports, simulation summaries, DVPR documentation, and thermal certification support documents.

Required Qualifications

Bachelor's or Master's degree in Mechanical Engineering, Aerospace Engineering, Thermal Engineering, or related discipline.
5+ years of industry experience in CFD, thermal management, or heat transfer analysis for aerospace, automotive, or electric propulsion systems.
Strong proficiency in STAR-CCM+, ANSYS Fluent, Simcenter, or equivalent CFD and thermal simulation software.
Experience with conjugate heat transfer (CHT), turbulence modeling, radiator flow analysis, and coolant flow simulations.
Strong understanding of electric motor and inverter thermal management techniques.
Knowledge of heat exchanger design, pump and coolant selection, and thermal packaging integration.
Familiarity with meshing techniques, solver setup, convergence studies, and post-processing methodologies.
Ability to interpret CFD results and translate findings into practical engineering design improvements.
Experience in validation testing and thermal instrumentation is highly desirable.

Nice To Have / Preferred Skills

Experience with aerospace propulsion systems, eVTOLs, UAVs, or electric aircraft programs.
Knowledge of battery thermal management systems and integrated propulsion cooling architectures.
Experience performing transient thermal simulations and mission-profile-based thermal analysis.
Exposure to high-voltage power electronics cooling systems and aerospace environmental requirements.
Familiarity with CAD tools such as CATIA, Siemens NX, or SolidWorks for thermal design integration.
Understanding of thermal runaway mitigation, phase-change materials, and advanced cooling technologies.
Hands-on experience with thermal test rigs, DAQ systems, and flow/temperature instrumentation.
Strong cross-functional collaboration skills with propulsion, controls, mechanical, and systems engineering teams.