Lead Thermal Simulation Engineer

The Consulting Solutions; Spain, San Francisco (TX, CA); On-site; USD 140,000 - 190,000; Full time

Benefits offered by this job

Relocation assistance

Job summary

The Consulting Solutions seeks a lead thermal simulation engineer to accelerate the design of next‑gen robotic systems through modeling, simulation, and analysis.

You will work with mechanical, electrical, controls, and robotics engineers to evaluate designs before hardware is built, identify risks early, and guide critical architecture decisions. The role spans structural and thermal analysis across actuators, mechanisms, structures, electronics, and integrated systems.

Qualifications

• Experience with thermal simulation of electromechanical systems.
• Ability to build and validate thermal models across subsystems.
• Strong collaboration with mechanical, electrical and controls engineers.

Responsibilities

• Perform thermal simulations to assess heat generation and cooling strategies.
• Develop and maintain simulation workflows and best practices.
• Correlate simulation results with physical testing and data.
• Support architecture trade studies and design decisions early in development.
• Lead and mentor junior engineers in thermal analysis methods.

Skills

First principles

Multidisciplinary problems

Hardware collaboration

Design optimization

Tools

Simcenter3D

Abaqus

Ansys

Nastran

LS-DYNA

COMSOL

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 SanFrancisco, CA. It will be expected to be in the 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 Simcenter3D, 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.

Background checks for applicants will be administered in accordance with applicable law, and qualified applicants with arrest or conviction records will be considered for employment consistent with those laws, including the SanFrancisco Fair Chance Ordinance, the LosAngeles County Fair Chance Ordinance for Employers, and the California Fair Chance Act, for US‑based candidates. For unincorporated LosAngeles County workers, we reasonably believe that criminal history may have a direct, adverse, and negative relationship with the following job duties, potentially resulting in the withdrawal of a conditional offer of employment.

We are committed to providing reasonable accommodations to applicants with disabilities; requests can be made via the application portal.