Lead Thermal Simulation Engineer

OpenAI; San Francisco (CA); On-site; USD 180,000 - 240,000; Full time

Benefits offered by this job

Relocation assistance

Job summary

OpenAI in San Francisco, CA seeks a lead thermal simulation engineer to drive design validation for next-gen robotic systems. You will model heat generation, cooling, interfaces, and system-wide thermal performance while partnering with mechanical, electrical, and controls engineers to shape early architecture decisions.

You will build and validate simulation workflows across actuators, mechanisms, structures, and integrated assemblies, correlating with physical tests to improve accuracy.

Qualifications

• Experience in thermal simulation of electromechanical systems.
• Ability to develop and validate simulation workflows.
• Proficiency with CAE tools such as Simcenter 3D, Abaqus, Ansys, Nastran, LS-DYNA, COMSOL, or equivalents.
• Experience correlating simulation with physical test data for high-volume products.
• Familiarity with robotic systems, actuators, power electronics, or integrated hardware.

Responsibilities

• Perform thermal simulations to assess heat generation, cooling strategies, interfaces, and system performance.
• Collaborate with mechanical, electrical, and controls engineers to influence early design decisions.
• Build simulation models for actuators, transmissions, mechanisms, structures, and assemblies.
• Correlate simulation with physical tests and improve model accuracy.
• Support architecture trade studies by evaluating design concepts before hardware is built.
• Develop simulation workflows, standards, and best practices across the robotics org.
• Identify risks and recommend design changes to improve performance, reliability, and manufacturability.
• Support root-cause investigations by integrating test data, failure analysis, and simulations.
• Contribute to long-term simulation capabilities including multiphysics modeling and digital twins.

Skills

Thermal simulation

Multiphysics

CAEs tools

Test-data correlation

Automation workflows

Tools

Simcenter 3D

Abaqus

Ansys

LS-DYNA

Job description

About the Team

Our Robotics team is focused on unlocking general-purpose robotics and pushing towards AGI-level intelligence in dynamic, real-world settings. Working across the entire model stack, we integrate cutting-edge hardware and software to explore a broad range of robotic form factors. We strive to seamlessly blend high-level AI capabilities with the constraints of physical systems to improve people's lives.

About the Role

We are seeking a lead thermal simulation engineer to help accelerate the design and development of next-generation robotic systems through modeling, simulation, and analysis. You will work closely with mechanical, electrical, controls, and robotics engineers to evaluate designs before hardware is built, identify risks early, and guide critical architecture decisions.

This role spans structural and thermal analysis and design across robotic subsystems including actuators, mechanisms, structures, electronics, and integrated systems. You will develop simulation workflows that improve engineering velocity, increase confidence in design decisions, and help us build more capable, reliable, and manufacturable robotic platforms.

This role is based in San Francisco, CA. This role will be expected to be in office 4 days per week and offer relocation assistance to new employees.

In this role, you will:

• Perform thermal simulations to assess heat generation, cooling strategies, thermal interfaces, and system-level thermal performance

• Partner with mechanical, electrical, and controls engineers to influence design decisions early in development

• Build simulation models to evaluate robotic actuators, transmissions, mechanisms, structures, soft goods, and integrated assemblies

• Correlate simulation results with physical testing and develop methodologies to improve model accuracy

• Support architecture trade studies by evaluating design concepts before hardware is built

• Develop simulation workflows, standards, and best practices that scale across the robotics organization

• Identify technical risks and recommend design changes to improve performance, reliability, and manufacturability

• Support root cause investigations by combining test data, failure analysis, and simulation results

• Contribute to long-term simulation capabilities including multiphysics modeling, digital twins, and system-level analysis

You might thrive in this role if you:

• Enjoy using first-principles engineering and simulation to solve complex multidisciplinary problems

• Are comfortable operating in ambiguous environments where simulation and design helps guide architecture decisions rather than simply validate finished designs

• Have strong intuition for mechanical systems and can connect simulation results to real-world hardware behavior

• Balance modeling rigor with practical engineering judgment and development speed

• Enjoy collaborating closely with hardware teams and influencing products from concept through deployment

Preferred qualifications:

• Experience performing thermal simulation and design of complex electromechanical systems

• Proficiency with commercial CAE tools such as Simcenter 3D, Abaqus, Ansys, Nastran, LS-DYNA, COMSOL, or equivalent platforms

• Experience correlating simulation models with physical test data and validation campaigns for high volume products

• Familiarity with robotic systems, actuators, mechanisms, power electronics, batteries, or other highly integrated hardware systems

• Experience developing simulation methodologies, automation tools, or organization-wide thermal workflows

We are an equal opportunity employer, and we do not discriminate on the basis of race, religion, color, national origin, sex, sexual orientation, age, veteran status, disability, genetic information, or other applicable legally protected characteristic.