CFD Engineer (CAE) – Propulsion and Battery Systems

General Motors Africa & Middle East; United States; Hybrid; USD 120,000 - 160,000; Full time

Job summary

General Motors Africa & Middle East is seeking a CFD Engineer – Propulsion and Battery Systems to lead DFMEA-driven 3D CFD analyses for thermal performance and reliability across propulsion systems, including batteries and power electronics. The role supports hybrid work arrangements and involves collaboration with internal and external stakeholders.

Responsibilities include conducting DFMEA-aligned CFD studies, validating mitigation designs, and communicating results through formal reviews.

Qualifications

• BS in Mechanical or Aerospace Engineering (or closely related field).
• 5+ years of experience with propulsion-related systems.
• Experience with 3D CFD software such as STAR-CCM+, Simerics-MP+, Fluent.
• Understanding of heat transfer and fluid mechanics.
• Experience with vehicle propulsion system design, operation, or testing.

Responsibilities

• Perform DFMEA-aligned 3D CFD analysis on high-voltage battery systems and power electronics to identify thermal failure modes.
• Simulate battery thermal runaway propagation, venting dynamics, and safety physics under severe abuse scenarios.
• Lead thermal risk assessments during architecture definition using rapid CFD trade studies.
• Correlate virtual failure mode predictions with physical test data for validation.
• Communicate analysis plans, assumptions, and results to stakeholders via reports and design reviews.
• Meet or exceed timing, quality, and cost targets within product development processes.
• Participate in benchmarking and advanced methods activities to improve GM's virtual CFD capabilities.

Skills

CFD software

Propulsion systems

Heat transfer

Fluid mechanics

DFMEA

Education

BS in Mechanical or Aerospace Engineering

Tools

STAR-CCM+

Simerics-MP+

Fluent

Job description

Job Description Role As a CFD Engineer – Propulsion and Battery Systems, you will lead DFMEA-driven 3D Computational Fluid Dynamics (CFD) analysis at the component, subsystem, and system level to optimize thermal performance and system reliability across GM propulsion systems. Operating within a DFMEA-centric environment, you will use virtual engineering to identify failure modes, evaluate severity/occurrence risks, and drive robust risk mitigation strategies for propulsion systems, specifically battery and power electronics thermal performance, durability and safety requirements.

Work Arrangement

Hybrid work position: This position does not require an employee to be on-site full-time to perform most effectively. The employee’s role enables them to work at a GM facility or off- site as frequently as needed or desired.

Primary Responsibilities

• Perform DFMEA-aligned 3D CFD analysis focusing on high-voltage battery systems and power electronics to identify and mitigate critical thermal failure modes at the cell, module, pack, and system level.
• Simulate and quantify battery Thermal Runaway Propagation (TRP), venting gas dynamics, and safety physics under severe abuse scenarios to validate DFMEA mitigation designs, barrier integrity, and failure containment controls.
• Lead thermal risk assessments during early architecture definition and concept selection using rapid CFD trade studies to eliminate high-risk failure modes prior to design freeze.
• Correlate virtual failure mode predictions with physical test and validation data to ensure simulation fidelity in predicting real-world failure thresholds and reliability margins.
• Clearly and effectively communicate analysis plans, assumptions, and results to internal and external stakeholders using presentations, reports, and design reviews.
• Meet or exceed timing, quality, and cost targets within structured product development processes.
• Participate in and/or lead benchmarking and advanced methods activities to continuously improve GM's virtual engineering capabilities in CFD and multi- physics analysis.

Required Skills and Experience

• 5+ years of experience with simulation, design, testing, or release of propulsion- related systems (e.g., engines, transmissions, e-drive units, batteries, power electronics, thermal management systems).
• Hands-on experience with at least one commercial 3D CFD software package (e.g., STAR-CCM+, Simerics-MP+, Fluent, or equivalent).
• Demonstrated understanding of heat transfer and fluid mechanics (conduction, convection, radiation, pressure loss, turbulence, etc.) applied to real engineering systems.
• Familiarity or practical experience with vehicle propulsion system design, operation, or testing.
• BS in Mechanical or Aerospace Engineering (or closely related field) required.

Preferred Skills and Experience

• 5+ years of advanced experience with 3D CFD thermal and fluid analysis specialized for battery pack and module systems.
• Experience in modeling battery Thermal Runaway Propagation (TRP) and gas venting dynamics under severe thermal abuse and cell failure conditions.
• Experience with electro-thermal multi-physics coupling, integrating electrochemical heat generation models with 3D CFD for cell characterization, module, and pack simulations.
• Expertise in Artificial Intelligence (AI), Machine Learning (ML), and Reduced Order Modeling (ROM) for rapid thermal prediction, digital twins, and real-time CFD surrogate modeling

GM does not provide immigration-related sponsorship for this role. Do not apply for this role if you will need GM immigration sponsorship now or in the future. This includes direct company sponsorship, entry of GM as the immigration employer of record on a government form, and any work authorization requiring a written submission or other immigration support from the company (e.g., H1-B, OPT, STEM OPT, CPT, TN, J-1, etc).

This role is categorized as hybrid. This means the selected candidate is expected to report to a specific location at least 3 times a week {or other frequency dictated by their manager}. Relocation benefits are available for candidates who qualify under company policy.

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