Senior CFD & Thermal Systems Engineer (Hybrid)

Kohler (Rehlko); Sheboygan (WI); Hybrid; USD 110,000 - 150,000; Full time

Job summary

Rehlko in Sheboygan, WI, is seeking a Staff Engineer, Simulation & Validation to lead thermal and fluid flow simulations and validate analytical results through experimental testing. You will contribute to engine cooling, power electronics cooling, and exhaust system optimization.

The role requires CFD expertise, heat transfer knowledge, and collaboration with engineering, testing, and supplier teams to improve performance and durability. Hybrid work mode with on-site location in Wisconsin.

Qualifications

• Bachelor's degree in mechanical engineering or a related engineering discipline.
• Minimum of six (6) years of engineering experience in thermal systems, fluid dynamics, simulation, validation, or related technical disciplines.
• Demonstrated experience applying CFD tools to solve complex engineering problems.
• Strong understanding of heat transfer, thermodynamics.

Responsibilities

• Lead thermal and fluid flow simulations to evaluate and optimize cooling system performance using CFD tools, including Siemens STAR-CCM+ and comparable technologies.
• Analyze and optimize engine thermal management systems, including radiators, fans, airflow distribution, cooling packages, and related components.
• Perform simulation and validation activities for fuel delivery, exhaust, and thermal management systems to ensure design and performance targets are achieved.
• Design, evaluate, and optimize heat transfer solutions for power electronics and related applications.
• Develop analytical methods, processes, and optimization tools that improve thermal system performance, robustness, and cost effectiveness.
• Conduct experimental testing and data analysis to correlate simulation models with physical validation results.
• Partner with product development engineers, laboratory teams, suppliers, and cross-functional stakeholders to solve complex engineering challenges.
• Develop and publish technical reports, engineering standards, validation procedures, best-practice guidelines, and technical documentation.
• Research and evaluate emerging simulation technologies and tools, recommending new capabilities that enhance engineering effectiveness and product performance.

Skills

CFD experience

Heat transfer

Thermal systems

Education

Bachelor's degree in mechanical engineering

Tools

Siemens STAR-CCM+

Job description

Rehlko in Sheboygan, WI, is seeking a Staff Engineer, Simulation & Validation to lead thermal and fluid flow simulations and validate analytical results through experimental testing. You will contribute to engine cooling, power electronics cooling, and exhaust system optimization.

The role requires CFD expertise, heat transfer knowledge, and collaboration with engineering, testing, and supplier teams to improve performance and durability. Hybrid work mode with on-site location in Wisconsin.