ERS Thermal Engineer

GMPPU; Concord (NC); On-site; USD 80,000 - 110,000; Full time

Job summary

GMPPU is looking for an ERS Thermal Engineer to join our team in Concord, NC. This role emphasizes thermal management for F1 power units, including MGU, CU-K, and ES systems. The engineer will be responsible for designing cooling strategies and performing thermal simulations to ensure performance and compliance.

The ideal candidate has a Bachelor's degree in Mechanical Engineering, at least 3 years of experience in thermal management, and strong knowledge of F1 ERS regulations and cooling techniques.

Qualifications

• 3+ years of experience in thermal management, preferably in motorsport or high-power electronics.
• Familiar with materials and processes for extreme environments.
• Specific knowledge of F1 ERS regulations and thermal design.

Responsibilities

• Design cooling systems for MGU-K, CU-K, and ES.
• Perform thermal simulations for analysis.
• Document thermal models and results for review.

Skills

Thermal management expertise

CFD tools proficiency (STAR-CCM+, ANSYS)

Heat transfer knowledge

Telemetry analysis

Education

Bachelor's degree in Mechanical Engineering or related field

Master's degree preferred

Tools

STAR-CCM+

ANSYS

SimScale

Job description

Overview

GM Performance Power Units (GM PPU) is seeking an ERS Thermal Engineer with a Formula 1 background to join our engineering team in Concord, NC. This role focuses on thermal management for Motor Generator Unit – e‑motor (MGU), Control Unit Kinetic – inverter (CU‑K), and Energy Store – battery (ES) systems in F1 power units. The engineer will deliver cooling strategies ensuring performance, reliability, and FIA compliance under extreme conditions.

Key Responsibilities

• Design cooling systems for MGU‑K, CU‑K, and ES, including heat exchangers, interfaces, and fluid routing.
• Perform thermal simulations using STAR‑CCM+, ANSYS, or equivalent for CFD/CHT analysis.
• Analyze telemetry data to optimize thermal performance across duty cycles.
• Collaborate with ERS, electronics, mechanical, and integration teams for system packaging.
• Support prototype testing (dyno, track, thermal cycling) and validation.
• Ensure DFM with suppliers for manufacturability and regulatory compliance.
• Document thermal models, results, and trade‑offs for review.

Required Qualifications

• Bachelor’s degree in Mechanical or related field; Master’s preferred.
• 3+ years in thermal management, preferably motorsport or high‑power electronics.
• Proficiency in CFD/thermal tools (STAR‑CCM+, ANSYS, SimScale).
• Strong heat transfer knowledge for electric motors, power electronics, batteries.
• Experience with materials and processes for extreme environments.
• Familiarity with F1 ERS regulations.
• Specific F1 ERS thermal design (MGU‑K, CU‑K, ES).
• Advanced cooling (oil spray, immersion, phase change).
• Thermal interface optimization and packaging in tight constraints.
• Telemetry analysis and controls integration.

Personal Attributes

• Innovative problem‑solver balancing trade‑offs.
• Excellent cross‑functional communicator.
• Detail‑oriented with continuous improvement mindset.
• Passionate about F1 technology.

Why Join Us

You’ll play a pivotal role in ensuring the reliability and performance of a next‑generation Formula 1 power unit. Our culture rewards precision, innovation, and the relentless pursuit of performance.