CFD Engineer (CAE) – Propulsion and Battery Systems

GM; Warren (MI); Hybrid; USD 120,000 - 160,000; Full time

Benefits offered by this job

Relocation benefits

Job summary

General Motors seeks an experienced CFD Engineer for Propulsion and Battery Systems to lead DFMEA-driven 3D CFD analyses, targeting thermal performance and reliability across battery and power electronics.

Hybrid work arrangement with on-site frequency as needed. Requires 5+ years in propulsion CFD and a BS in Mechanical or Aerospace Engineering; familiarity with STAR-CCM+, Fluent, or Simerics-MP+ is expected.

Qualifications

• 5+ years with propulsion-related CFD/design/test/release.
• Hands-on with at least one commercial 3D CFD package (STAR-CCM+, Fluent, etc.).
• Understanding of heat transfer and fluid mechanics applied to engineering systems.
• Familiarity with vehicle propulsion system design, operation, or testing.
• BS in Mechanical or Aerospace Engineering is required.

Responsibilities

• Perform DFMEA-aligned 3D CFD analysis for high-voltage battery systems and power electronics to identify and mitigate thermal failure modes at cell, module, pack, and system levels.
• Simulate and quantify battery Thermal Runaway Propagation, venting dynamics, and safety physics under severe abuse scenarios to validate DFMEA mitigation designs.
• Lead thermal risk assessments during early architecture definition and concept selection using rapid CFD trade studies.
• Correlate virtual predictions with physical test data to ensure simulation fidelity and reliability margins.
• Communicate analysis plans, assumptions, and results to stakeholders via presentations, reports, and design reviews.
• Meet timing, quality, and cost targets within product development processes.
• Participate in benchmarking and advanced methods to improve GM’s virtual engineering capabilities in CFD and multi-physics.

Skills

DFMEA CFD

3D CFD Software

Heat transfer

Propulsion familiarity

Mechanical/Aerospace BS

Education

Bachelor's in Mechanical or Aerospace Engineering

Tools

STAR-CCM+

Fluent (CFD)

Simerics-MP+

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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