Research Engineer- Fuel Cell Stack Modeling

Ford; Dearborn (MI); Hybrid; USD 99,100 - 166,200; Full time

Benefits offered by this job

Medical, dental, vision coverage

Family care days and parental leave

Vehicle discount program

Job summary

Ford is seeking a Research Engineer in Fuel Cell Stack Modeling to advance clean energy vehicle technologies. In this role, you will design and execute simulations of fuel cell stack operations, contributing to system-level design decisions and mitigation of stack stress factors.

The ideal candidate will have a degree in Engineering or Physics, experience with MATLAB and Simulink, and a strong foundation in fuel cell technology. The position is hybrid, with opportunities for significant collaboration across teams.

Qualifications

• Two or more years of experience with fuel cell stack simulation.
• Experience in troubleshooting complex simulation models.
• Strong communication skills for documentation and collaboration.

Responsibilities

• Develop and improve fuel cell stack performance models.
• Conduct model-based engineering analysis.
• Collaborate with hardware engineers on simulations.

Skills

MATLAB

Simulink

Programming (C, Python, LabVIEW)

Fuel Cell Technology Knowledge

Electrochemistry Principles

Complex Simulation Troubleshooting

Education

B.S. or M.S. in Engineering/Physics

Ph.D. in relevant field (preferred)

Tools

Fluent

COMSOL

AVL Fire M

Git/GitHub

Job description

Job Description

As a Research Engineer in Fuel Cell Stack Modeling, you will play a pivotal role in advancing Ford’s clean energy vehicle technologies. You will design and execute high‑fidelity simulations that capture the complex physics of automotive fuel cell stack operations. Working at the intersection of virtual simulation and physical testing, you will collaborate closely with hardware engineers, control systems teams, and external research partners. Your work will directly influence system‑level design decisions, helping to mitigate stack stress factors, extend fuel cell lifetimes, and deliver scalable, production‑ready green energy solutions.

Responsibilities

• Develop and improve physical and electrochemical models to predict fuel cell stack performance, degradation, and internal operational states.
• Conduct model‑based engineering analysis to mitigate stack stress factors and improve lifetime durability, supporting key design decisions for fuel cell stacks, systems, and controls.
• Create advanced simulations incorporating the physics of automotive fuel cell stack operation to develop and verify current and future system designs.
• Develop software toolsets for simulated fuel cell stacks to test against physical constraints and safe operational requirements.
• Implement automation processes for the analysis and testing of modeled fuel cell stacks.
• Develop standardized processes, methods, and tools to make simulation models shareable and scalable across departments.
• Analyze and review simulation test data using real‑time and post‑processing tools to ensure tight correlation between virtual models and physical testing.
• Integrate fuel cell stack simulation models with other Ford models, including controls, larger powertrain systems, and full‑vehicle simulations.
• Work closely with hardware test engineers to design physical experiments, parameterize physics‑based models, and troubleshoot complex system‑level issues.
• Collaborate closely with other department teams, internal modelers, and external partners such as universities and automotive suppliers.
• Create and maintain comprehensive simulation documentation (including requirements, procedures, plans, and reports), document simulation code, and publish technical papers or reports.

Qualifications

• B.S. or M.S. in Electrical Engineering, Mechanical Engineering, Chemical Engineering, Physics, or a related field.
• Two or more years of experience with open‑loop and closed‑loop fuel cell stack simulation.
• Demonstrated foundational knowledge of fuel cell technology, electrochemistry principles, and fuel cell system operations (academic or industry‑based).
• Experience working with data from fuel cell testing (e.g., electrochemical impedance spectroscopy, cyclic voltammetry, etc.).
• Three or more years of experience using MATLAB and Simulink for component and system modeling.
• One or more years of experience formulating transfer functions and developing complex simulations.
• Proven experience in troubleshooting and solving complex simulation model errors.
• Demonstrated systems engineering mindset.
• Strong oral, visual, and written communication skills with a proven ability to document processes and simulation designs clearly.
• Ph.D. in Electrical Engineering, Mechanical Engineering, Chemical Engineering, Physics, or a related field (preferred).
• Specialized experience in modeling and methods for evaluating Proton Exchange Membrane (PEM) fuel cell degradation.
• Experience with high‑fidelity simulation software such as Fluent, COMSOL, AVL Fire M, or other multiphysics CFD programs.
• Familiarity interfacing models with system simulation software such as AVL Cruise M, Simulink, or similar platforms.
• High level of expertise in programming and software development for model creation (e.g., MATLAB, C, Python, LabVIEW).
• Experience using distributed version control software such as Git or GitHub.

Benefits

• Immediate medical, dental, vision and prescription drug coverage.
• Flexible family care days, paid parental leave, new‑parent ramp‑up programs, subsidized backup child care and more.
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more.
• Vehicle discount program for employees and family members and management leases.
• Established and active employee resource groups.
• Paid time off for individual and team community service.
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day.
• Paid time off and the option to purchase additional vacation time.

Salary range: $99,100 - $166,200 (salary grade 8).

Visa sponsorship is not available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.

We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status, or protected veteran status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1‑888‑336‑0660.

This position is hybrid. Candidates who are in commuting distance to a Ford hub location may be required to be onsite four or more days per week.