Job Description

Looking for - Thermal Engineer/Battery Simulation Engineer - Cupertino, CA

We are seeking a highly skilled Thermal / Multiphysics Simulation Engineer to develop state-of-the-art finite element (FE) models for battery cells, packs, and subsystems. In this role, you will be responsible for creating simulation capabilities that accurately translate power dissipation into thermal outputs, performing advanced thermal CAE simulations, and validating models against physical test data. You will collaborate closely with system engineering and reliability teams to optimize workflows, establish best practices, and contribute to the design of next-generation battery systems.

Key Responsibilities

• Develop and maintain thermal and Multiphysics FE models of battery cells, packs, and client subsystems.

• Generate modeling capability to convert power maps into thermal outputs for accurate system predictions.

• Perform advanced thermal CAE simulations to evaluate and understand boundary conditions at different levels (cell, pack, subsystem).

• Use best-in-class CAE tools and solvers (e.g., ANSYS, Abaqus, COMSOL, Star-CCM+) to develop accurate simulation models.

• Collaborate with test and reliability labs to design physical test methods, gather experimental data, and validate simulation results.

• Work with system and design teams to develop detailed sub-models for integration into assembly-level simulations.

• Establish optimized workflows and reusable templates for regularly required thermal simulations to improve efficiency.

• Define and implement simulation best practices, methodologies, and guidelines to ensure consistent, reliable results.

Required Qualifications

• 5 10+ years of experience in thermal/structural/Multiphysics simulation using FEA/CFD tools.

• Strong expertise in thermal modeling of electro-mechanical or battery systems.

• Hands-on experience with ANSYS, Abaqus, COMSOL, Star-CCM+, or similar CAE tools.

• Knowledge of heat transfer, fluid dynamics, materials behavior, and Multiphysics coupling.

• Experience working with physical test labs for model correlation and validation.

• Strong programming/scripting skills (Python, MATLAB, or similar) to automate simulation workflows.

• Excellent communication skills with ability to collaborate across cross-functional teams.

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