Thermal Systems Engineer – Vehicle & Battery

ESP Engineered; Bengaluru; On-site; INR 800,000 - 1,200,000; Full time

Job summary

ESP Engineered in Bengaluru is seeking an experienced Thermal Systems Engineer for Vehicle & Battery. The role demands expertise in CFD-based thermal analysis for EV battery packs and powertrain systems. Candidates should possess strong design skills in cooling systems and a solid background in automotive systems for collaborative execution and validation.

The ideal candidate has 3–7 years of industry experience, preferably in direct involvement with vehicle or battery pack programs, and is proficient with ANSYS Fluent and CAD tools such as SolidWorks.

Qualifications

• 3–7 years of relevant industry experience.
• Background in EVs, automotive systems, or power electronics.
• Direct involvement in at least one running vehicle program or battery pack.

Responsibilities

• Perform CFD-based thermal simulations using ANSYS Fluent / Star-CCM+.
• Design and optimize cooling plates and ducts.
• Define and support sensor placement for validation.

Skills

CFD-based thermal analysis

ANSYS Fluent

Vehicle thermal management

Cooling system design

Education

Bachelor’s or Master’s degree in Mechanical, Automotive, Electrical, or Thermal Engineering

Tools

ANSYS Fluent

Star-CCM+

SolidWorks

CATIA

NX

Job description

Thermal Systems Engineer – Vehicle & Battery

02 - 04 Years

Full-Time

Job Purpose

We are looking for a Thermal Systems Engineer – Vehicle & Battery with strong experience in CFD-based thermal analysis for EV battery packs and powertrain systems. The role involves end‑to‑end ownership of thermal simulations, cooling system design, vehicle-level integration, and correlation with test data. The ideal candidate has hands‑on experience working on at least one running vehicle or battery pack program.

Key Responsibilities and Deliverables

1. Simulation & Analysis (50%)

• Perform CFD-based thermal simulations using ANSYS Fluent / Star-CCM+ (mandatory).
• Battery pack thermal analysis at cell-level and module-level, including steady‑state and transient cases.
• Thermal simulation of inverter and motor cooling systems.
• Under‑hood and under‑body airflow and thermal management studies.
• Analyze Joule heating and electrical losses in:
  • Busbars, tabs, connectors
  • High-current transient operating conditions
• Support thermal runaway mitigation, venting, and safety studies (good to have).
• Prepare simulation reports with clear design recommendations.

2. Design & Packaging (30%)

• Design and optimize cooling plates, ducts, and flow paths.
• Perform fan and pump sizing based on thermal and hydraulic requirements.
• Package thermal systems at the vehicle level, considering space, manufacturability, and serviceability.
• Work closely with CAD teams using SolidWorks / CATIA / NX to implement thermal solutions.
• Support design trade-offs between performance, cost, weight, and packaging constraints.

3. Execution & Validation (20%)

• Define and support sensor placement (NTCs, RTDs, thermocouples) for validation.
• Correlate CFD results with vehicle, dyno, and bench test data.
• Coordinate with vendors for radiators, pumps, hoses, and thermal components.
• Support vehicle testing, dyno testing, and on‑road validation activities.
• Troubleshoot thermal issues observed during testing and production trials.

Desired Qualifications: Required Qualifications, Knowledge, and Experience

Required Qualifications

• Bachelor’s or Master’s degree in Mechanical, Automotive, Electrical, or Thermal Engineering
• 3–7 years of relevant industry experience
• Background in EVs, automotive systems, or power electronics
• Direct involvement in at least one running vehicle program or battery pack

Knowledge and Experience

• Strong expertise in ANSYS Fluent or Star-CCM+ (non‑negotiable)
• Working experience with Icepak (strong plus)
• Practical understanding of:
  • Battery thermal management systems
  • Motor and inverter cooling
  • Vehicle‑level airflow and heat rejection
• CAD experience using SolidWorks / CATIA / NX
• Basic proficiency in MATLAB for data analysis and post‑processing
• Familiarity with thermal testing, validation, and correlation methods
• Ability to work effectively with incomplete or evolving data
• Strong engineering judgment beyond simulation results
• Comfortable with fast iteration cycles and startup‑style execution
• Hands‑on mindset with shop‑floor and test‑track interaction
• Clear communication with cross‑functional teams (design, testing, vendors)
• Problem‑solving approach focused on real‑world performance, not just “CFD says OK”