CFD Engineer (CAE) – Propulsion and Battery Systems

General Motors Corporation; Warren (MI); Hybrid; USD 110,000 - 150,000; Full time

Job summary

General Motors in Warren, Michigan is seeking a CFD Engineer (Propulsion and Battery Systems) to lead DFMEA-driven 3D CFD analyses for battery packs and propulsion components. You will assess thermal performance and reliability, simulate thermal runaway and venting dynamics, and work across architecture stages to mitigate risks.

The role requires DFMEA alignment, extensive CFD experience, and a strong physics foundation.

Qualifications

• Must have DFMEA-aligned CFD experience for propulsion-related systems.
• Strong background in heat transfer, fluid mechanics, and thermodynamics.
• Experience with high-voltage battery systems, power electronics, and thermal management.

Responsibilities

• Perform 3D CFD analyses aligned with DFMEA for battery packs and power electronics.
• Simulate battery thermal runaway propagation and venting dynamics under abuse scenarios.
• Lead thermal risk assessments during early architecture and concept selection.
• Correlate CFD predictions with test data to ensure reliability margins.
• Communicate analysis plans and results to stakeholders via reviews and reports.
• Meet timing, quality, and cost targets within product development processes.

Skills

DFMEA

CFD

Heat transfer

Education

BS Mechanical or Aerospace Engineering

Tools

STAR-CCM+

Simerics-MP+

Fluent (CFD)

Job description

## CFD Engineer (CAE) – Propulsion and Battery SystemsApply: Hybrid: Warren, Michigan, United States of America: Full time: Posted Today: JR-202605368**Job Description**RoleAs a CFD Engineer – Propulsion and Battery Systems, you will lead DFMEA-driven 3DComputational Fluid Dynamics (CFD) analysis at the component, subsystem, andsystem level to optimize thermal performance and system reliability across GM propulsionsystems. Operating within a DFMEA-centric environment, you will use virtual engineeringto identify failure modes, evaluate severity/occurrence risks, and drive robust riskmitigation strategies for propulsion systems, specifically battery and power electronicsthermal performance, durability and safety requirements.Work ArrangementHybrid work position: This position does not require an employee to be on-site full-time toperform 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 systemsand power electronics to identify and mitigate critical thermal failure modes at thecell, module, pack, and system level.● Simulate and quantify battery Thermal Runaway Propagation (TRP), venting gasdynamics, and safety physics under severe abuse scenarios to validate DFMEAmitigation designs, barrier integrity, and failure containment controls.● Lead thermal risk assessments during early architecture definition and conceptselection using rapid CFD trade studies to eliminate high-risk failure modes prior todesign freeze.● Correlate virtual failure mode predictions with physical test and validation data toensure simulation fidelity in predicting real-world failure thresholds and reliabilitymargins.● Clearly and effectively communicate analysis plans, assumptions, and results tointernal and external stakeholders using presentations, reports, and design reviews.● Meet or exceed timing, quality, and cost targets within structured productdevelopment processes.● Participate in and/or lead benchmarking and advanced methods activities tocontinuously 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, powerelectronics, 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 engineeringsystems.● 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 analysisspecialized for battery pack and module systems.● Experience in modeling battery Thermal Runaway Propagation (TRP) and gasventing dynamics under severe thermal abuse and cell failure conditions.● Experience with electro-thermal multi-physics coupling, integratingelectrochemical heat generation models with 3D CFD for cell characterization,module, and pack simulations.● Expertise in Artificial Intelligence (AI), Machine Learning (ML), and ReducedOrder Modeling (ROM) for rapid thermal prediction, digital twins, and real-timeCFD 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.