Simulation & Modeling Engineer

Heller Industries; New Jersey; On-site; USD 95,000 - 135,000; Full time

Job summary

Heller Industries seeks a Simulation & Modeling Engineer to lead CFD, thermal, and structural simulations for advanced thermal processing equipment across electronics, semiconductor, and industrial markets.

You will develop and validate models, optimize airflow and heat transfer, and collaborate with multiple engineering teams to reduce prototyping and accelerate product development.

Qualifications

• Bachelor's degree in Mechanical Engineering or related discipline required.
• 3+ years of engineering simulation experience.
• Proficiency with ANSYS Fluent, ANSYS Mechanical, SolidWorks, SolidWorks Flow Simulation.

Responsibilities

• Develop CFD models of thermal processing equipment using ANSYS Fluent and SolidWorks Flow Simulation.
• Model airflow distribution, pressure losses, turbulence, fan performance, and recirculation systems.
• Analyze and optimize nozzle configurations, plenums, ductwork, dampers, and process chamber airflow.
• Develop transient and steady-state thermal models; perform heat transfer analyses (conduction, radiation, forced convection).
• Perform structural FEA with ANSYS Mechanical and SolidWorks Simulation; assess thermal growth and fatigue.

Skills

Fluid dynamics

Heat transfer

Thermodynamics

Engineering mechanics

Simulation reporting

Education

Bachelor's degree in Mechanical Engineering

Master's degree in Thermal Sciences or CFD (preferred)

Tools

ANSYS Fluent

ANSYS Mechanical

SolidWorks

SolidWorks Flow Simulation

Job description

Heller Industries is seeking a highly motivated Simulation & Modeling Engineer to lead the development and application of advanced simulation tools supporting thermal processing equipment used in electronics, semiconductor, aerospace, automotive, and industrial manufacturing industries.

The Simulation & Modeling Engineer will be responsible for developing, validating, and applying computational models to improve thermal performance, airflow uniformity, energy efficiency, reliability, and product throughput across Heller's product portfolio. The primary focus will be computational fluid dynamics (CFD), heat transfer analysis, thermal optimization, and multiphysics simulation utilizing ANSYS and SolidWorks simulation tools.

This position will work closely with Mechanical Engineering, Electrical Engineering, Software Engineering, Product Management, Manufacturing, and Applications Engineering teams to accelerate product development and reduce physical prototype iterations through first-principles simulation and data-driven engineering.

Primary Responsibilities

CFD and Airflow Analysis

• Develop CFD models of thermal processing equipment using ANSYS Fluent and SolidWorks Flow Simulation.
• Model airflow distribution, pressure losses, turbulence characteristics, fan performance, and recirculation systems.
• Optimize nozzle configurations, plenums, ductwork, dampers, and process chamber airflow.
• Analyze gas flow behavior within:
• SMT reflow ovens
• Vacuum reflow systems
• Formic acid processing equipment
• Pressure curing ovens
• Drying systems
• Convection and hybrid thermal systems
• Predict and improve thermal uniformity across process chambers.

Thermal System Modeling

• Develop transient and steady-state thermal models.
• Perform heat transfer analysis involving:
• Conduction
• Radiation
• Forced-air hating
• Multi-zone thermal systems
• Predict product temperatures and process profiles.
• Evaluate heater placement, insulation effectiveness, and thermal efficiency
• Support development of new thermal technologies and process architectures.

Mechanical and Structural Simulation

• Perform structural FEA using ANSYS Mechanical and SolidWorks Simulation.
• Analyze:
• Thermal growth and distortion
• Conveyor and rail deflection
• Fan wheel stress
• High-temperature material performance
• Fatigue and wear concerns
• Evaluate critical mechanical subsystems subjected to thermal cycling.

Product Development Support

• Support New Product Development (NPD) programs from concept through production release.
• Participate in design reviews and provide simulation-based recommendations.
• Develop performance predictions for proposed concepts.
• Generate engineering reports to support design decisions.
• Identify root causes of system performance limitations.

Validation and Correlation

• Correlate simulation predictions with laboratory and field measurements.
• Design experiments to validate:
• Airflow velocity
• Thermal profiles
• Improve model accuracy through iterative validation.
• Develop simulation best practices and standards.

Customer and Field Support

• Assist field teams in troubleshooting thermal and airflow-related performance issues.
• Support process development activities at customer sites.
• Thermal uniformity concerns
• Airflow imbalances
• Energy efficiency opportunities
• Product profile concerns

Required Qualifications

• Bachelor's degree in Mechanical Engineering or related discipline.
• 3+ years of engineering simulation experience.
• Proficiency with: ANSYS Fluent; ANSYS Mechanical; SolidWorks; SolidWorks Flow Simulation.
• Strong understanding of: Fluid dynamics; Heat transfer; Thermodynamics; Engineering mechanics.
• Experience generating technical reports and engineering recommendations.
• Ability to interpret and communicate complex simulation results.

Preferred Qualifications

• Master's degree in Mechanical Engineering with concentration in Thermal Sciences, CFD, or Computational Engineering.
• Experience with semiconductor or SMT manufacturing equipment.
• Experience with: Multi-phase flow; Forced convection systems; High-temperature equipment; Vacuum systems; Process equipment development.
• Familiarity with: MATLAB; Python; Design of Experiments (DOE); Statistical analysis.
• Experience performing simulation correlation using empirical test data.

Desired Technical Skills

CFD

• Turbulence modeling
• Flow visualization
• Particle tracking
• Fan and blower modeling
• Flow optimization

Thermal Analysis

• Transient heat transfer
• Thermal response prediction
• Radiation modeling
• Thermal uniformity analysis
• Energy balance calculations

Mechanical Analysis

• Static structural analysis
• Thermal stress analysis
• Fatigue assessment
• Vibration analysis

Key Success Metrics

The successful candidate will:

• Reduce physical prototype requirements through simulation-driven development.
• Improve thermal uniformity across thermal processing platforms.
• Improve airflow performance and system efficiency.
• Accelerate design cycles through predictive modeling.
• Improve first-pass success rates of NPD programs.
• Establish simulation methodologies that become standard engineering practices across Heller's product portfolio.

This role is intended to become Heller's technical expert in:

• CFD
• Thermal system modeling
• Airflow optimization
• Thermal process development
• Digital engineering and simulation-driven design

Potential progression: Simulation Engineer III -> Senior Simulation Engineer IV -> Principal Engineer -> Thermal Systems Architect