Sr Engineer Systems - Thermal/CFD

Harley-Davidson Motor Company; Wauwatosa (WI); On-site; USD 93,400 - 145,000; Part time

Benefits offered by this job

Annual bonus

Health insurance

401(k)

Onsite fitness centers

Employee stores

Product discounts

Job summary

Harley-Davidson Motor Company in Wauwatosa, WI seeks a Sr Engineer Systems - Thermal/CFD to advance vehicle aerodynamics, thermal comfort, and powertrain development through 3-D CFD analysis and simulations onsite.

The role collaborates with motorcycle project teams, design studios, test labs, and external partners to deliver innovative solutions for current production issues and future product plan projects.

Qualifications

• Minimum 5 years of 3-D CFD simulations in battery enclosure heat transfer, ICE heat transfer, powertrain, vehicle aerodynamics, and thermal comfort.
• Strong understanding of thermodynamics, fluid flow, heat transfer, and combustion.
• Experience with CFD tools (Star-CCM+, Converge, GT-Power, modeFrontier, Sculptor, TaiTherm, Simulink, Optistruct).
• Experience with data sets and CFD correlation (Powertrain, Dyno, Vehicle, Wind tunnel).
• Proficiency in programming with MATLAB, Python, Java and related tools.
• Familiarity with Creo and CFD mesh repair techniques.
• Excellent verbal and written communication skills; strong problem-solving abilities.

Responsibilities

• Retrieve, prepare, and clean CAD parts for CFD volume meshing.
• Collaborate with internal customers to ensure proper boundary conditions are applied.
• Develop 3-D/1-D CFD/CAE models to analyze thermodynamics, fluid flow, and heat transfer.
• Develop 3-D/1-D thermal models for heat conduction, convection, and radiation.
• Model components such as powertrain, battery cases, motors, metals, coatings, and battery cells.
• Develop 3-D/1-D thermal models for power electronics and motor cooling.
• Analyze 3-D/1-D models to identify opportunities for overall vehicle improvements.
• Communicate across software tools to quantify or optimize vehicle performance.
• Interpret results and translate findings into practical design suggestions.
• Validate results with real-world data and drive model improvements.

Skills

Programming: MATLAB

Python

Java

Education

Bachelor’s Degree in Mechanical Engineering (Fluids/Heat Transfer/Combustion)

Master’s or PhD with CFD specialization (preferred)

Tools

Star-CCM+

Converge

GT-Power

modeFrontier

Sculptor

TaiTherm

Simulink

Optistruct

Creo

Job description

Overview

Harley-Davidson Motor Company is seeking a Sr Engineer Systems - Thermal/CFD for the Product Development Center (PDC) in Wauwatosa, WI. This onsite, part-time role supports vehicle aerodynamics, thermal comfort, and powertrain development (ICE/EV) through 3-D CFD simulation and analysis. The position collaborates with motorcycle project teams, design studio, test labs, and external partners to deliver innovative solutions for current production issues and future product plan projects.

Job Summary

The Senior Systems Engineer - Thermal/CFD is a full-time onsite position reporting to the System/Component Simulation Engineering Manager. The role provides 3-D CFD simulation and analysis to support vehicle aerodynamics, thermal comfort, and powertrain development, aligning with cross-functional strategies within product development.

Responsibilities

• Retrieve, prepare, and clean CAD parts for CFD volume meshing
• Collaborate with internal customers to ensure proper boundary conditions are applied
• Work with Powertrain, Electrical, Mechanical, and Reliability engineers to develop simulation cases and physical tests in parallel to validate and refine 3-D/1-D models
• Develop 3-D/1-D CFD/CAE models to analyze thermodynamics, fluid flow, and heat transfer (lubrication, cooling, air and other means)
• Develop 3-D/1-D thermal models of heat conduction, convection, and radiation to support thermal design decisions and their impact on vehicle components (rider/passenger)
• Model components such as powertrain, battery cases, motors, metals, non-metals, gap fillers, conduction interfaces, coatings, and battery cells
• Develop 3-D/1-D thermal models for power electronics and motor cooling, including motor windings and rotor interior
• Develop 3-D/1-D thermal convection models for understanding ICE/EV energy balance
• Analyze 3-D/1-D models to identify opportunities for overall vehicle/system improvements (pressure loss, heat transfer, energy balance, flow and drag)
• Communicate across software tools to quantify or optimize vehicle/sub-system performance (Star-CCM+, GT-Power, Sculptor, ModeFrontier, Simulink)
• Interpret analysis results in relation to lab testing and translate findings into practical design suggestions
• Validate/correlate results with real-world data and drive model improvements for methods development
• Generate high-level engineering reports and present CFD/CAE results and conclusions to motorcycle project teams

Education Requirements

Bachelor’s Degree Required

Education Specifications

Position requires a bachelor’s degree in one of the following disciplines: Mechanical Engineering (Fluids, Heat Transfer, or Combustion emphasis), Aerospace/Aeronautical Engineering, or Applied Physics. Master’s degree or PhD with specialization in CFD is preferred.

Experience Requirements

The successful candidate will have a minimum of 5 years of related experience, including:

• Demonstrated history of 3-D CFD simulations in battery enclosure heat transfer, ICE heat transfer, powertrain applications, vehicle aerodynamics, and thermal comfort
• Strong understanding of thermodynamics, fluid flow, heat transfer, and combustion
• Experience with CFD tools (e.g., Star-CCM+, Converge, GT-Power, modeFrontier, Sculptor, TaiTherm, Simulink, Optistruct)
• Experience with data sets and CFD correlation (Powertrain, Dyno, Vehicle, Wind tunnel)
• Experience in parallel computations, parametric modeling, and design optimization
• Proficiency in programming with MATLAB, Python, Java, and related tools
• Familiarity with Creo and CFD mesh repair techniques
• Excellent verbal and written communication skills
• Strong interpersonal and problem-solving abilities
• Demonstrated technical problem-solving capability

The pay range shown represents the national average for this role. Pay may vary by location and experience.

We offer an inclusive compensation package for all full-time salaried employees including annual bonuses, health insurance, 401(k), onsite fitness centers and employee stores, product discounts, and more. Learn more about Harley-Davidson here.

Additional Information

Applicants must be authorized to work in the United States. Direct Reports: Yes. Travel: 0-10%. Pay Range: $93,400 - $145,000. Visa Sponsorship: Not eligible. Relocation: Domestic relocation assistance available within the posted country.