CFD Engineer: Propulsion & Battery Thermal Systems

General Motors; Warren (MI); Hybrid; USD 120,000 - 180,000; Full time

Benefits offered by this job

Hybrid work arrangement

Relocation benefits

Job summary

General Motors is seeking a CFD Engineer focusing on propulsion and battery systems. You will lead DFMEA-driven 3D CFD analyses to optimize thermal performance across cells, modules, and packs, with emphasis on safety and reliability of high-voltage systems.

The role requires deep knowledge of heat transfer, fluid mechanics, and 3D CFD tools, plus experience in propulsion-related engineering. Hybrid work style and relocation support are available to qualified candidates.

Qualifications

• BS in Mechanical or Aerospace Engineering or closely related field.
• 5+ years of experience with propulsion-related system simulation, design, testing, or release.
• Hands-on experience with STAR-CCM+, Simerics-MP+, Fluent or equivalent CFD tools.
• Understanding of heat transfer and fluid mechanics in engineering systems.
• Familiarity with vehicle propulsion system design, operation, or testing.

Responsibilities

• Perform DFMEA-aligned 3D CFD analysis focusing on 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 gas dynamics, and safety physics under severe abuse scenarios to validate DFMEA mitigation designs.
• Lead thermal risk assessments during early architecture definition using rapid CFD trade studies to eliminate high-risk failure modes before design freeze.
• Correlate virtual failure mode 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 structured product development processes.
• Participate in benchmarking and advanced methods activities to improve GM’s virtual CFD capabilities.

Skills

CFD simulations

DFMEA-driven analysis

High-voltage battery systems

Thermal management

3D CFD software

Education

BS in Mechanical or Aerospace Engineering

Tools

STAR-CCM+

Simerics-MP+

Fluent

Job description

General Motors is seeking a CFD Engineer focusing on propulsion and battery systems. You will lead DFMEA-driven 3D CFD analyses to optimize thermal performance across cells, modules, and packs, with emphasis on safety and reliability of high-voltage systems.

The role requires deep knowledge of heat transfer, fluid mechanics, and 3D CFD tools, plus experience in propulsion-related engineering. Hybrid work style and relocation support are available to qualified candidates.