Sr. Simulation & Analysis Engineers – Battery & Charger Development Brookfield, WI

Techtronic Industries; Town of Brookfield (WI); On-site; USD 100,000 - 150,000; Full time

Job summary

Techtronic Industries is seeking a Sr. Simulation & Analysis Engineer for Battery & Charger Development in Brookfield, WI. You will lead the battery pack and electro/thermal design, develop best practices for modeling, and guide design decisions through simulations.

The role requires a Master’s or Bachelor’s in Mechanical Engineering with 2–5 years of related experience, plus strong skills in MATLAB/Simulink, Ansys, Python, and DOE. Travel up to 10% is possible.

Qualifications

• Battery cell, pack level simulation and testing experience.
• Experience with heat generation and failure-mode modeling for Li‑Ion batteries.
• Mathematical modeling of electrochemical behavior in Li-ion cells.
• Programming and simulation with Python and MATLAB/Simulink.
• DOE and statistical data analysis experience.
• Ability to lead project teams and present technical content.

Responsibilities

• Lead team on battery pack and electro/thermal design.
• Develop best practices for battery pack modeling and simulation.
• Balance mechanical, electrical, and fluids simulations for heating/cooling.
• Identify, develop, and maintain simulation tools for predicting performance, thermals, and failures.
• Use simulation results to inform design decisions and improve reliability.
• Establish test regimens for pack thermals within project scope.
• Deliver complete data analysis to support design recommendations.
• Lead test plans and project resources to improve simulations.
• Present technical content to stakeholders.
• Collaborate with design engineers to integrate simulation early in design stage.
• Lead electro/mechanical, fluid, DOE, and statistics analyses.
• Conduct vibration testing and use IR camera, thermocouples, laser vibrometer, and strain gauges.

Skills

Battery modeling

Electro-thermal analysis

DOE design of experiments

Data analysis

Python programming

Project leadership

Education

Master's degree in Mechanical Engineering

Bachelor's degree in Mechanical Engineering

Tools

MATLAB/Simulink

Ansys

nCode

OptiSlang

MINITAB

Job description

Sr. Simulation & Analysis Engineers – Battery & Charger Development

Sr. Simulation & Analysis Engineers – Battery & Charger Development

13135 W Lisbon Road, Brookfield, WI 53005

Job Duties

• Lead team on battery pack and electro/thermal design.
• Lead in developing best practices for battery pack level modeling and simulation.
• Balance use of mechanical, electrical, and fluids flow simulation as it pertains to pack heating and cooling.
• Lead in identification, development, and maintenance of simulation tools for predicting battery pack performance, thermals, and failure modes.
• Use simulation results to guide design decisions and optimize battery performance, reliability, and safety.
• Establish test regimens for pack level thermals within scope of the project.
• Deliver complete data analysis to support design recommendations.
• Lead, develop, and implement test plans and project resources to correlate and improve simulation results.
• Present technical content.
• Collaborate with design engineers to incorporate simulation early in the design stage. May manage project team members.
• Lead the execution of a wide variety of engineering analyses including electro/mechanical simulation, fluid and mass transfer, Design of Experiments, and statistical data analysis.
• Conduct vibration analysis, test, and additional test capabilities including IR Camera, Thermocouple, Laser Vibrometer, and strain-gauge.

Master’s degree in Mechanical Engineering, related engineering field, or foreign degree equivalent, and 2 years of relevant experience as an Engineer, or alternate related acceptable occupation; OR Bachelor’s degree in Mechanical Engineering, related engineering field, or foreign degree equivalent, and 5 years of relevant experience as an Engineer, or alternate related acceptable occupation.

Work or academic experience must have included:

1. Battery cell, pack level simulation, and test (Structural, Thermal CFD, MATLAB / Simulink, Ansys, DOE, and Test Methodology).

2. Developing models related to heat generation, failure-mode, and cycle life prediction for Li‑Ion batteries.

3. Mathematical modeling of electrochemical behavior of lithium‑ion battery cells (single particle model, Newman P2D model, NTGK & DCiR model, ECM, 3D detailed and coupled multi-physics model).

4. Programming and Simulation tools (Python, MATLAB, Simulink, and Ansys Products, nCode, OptiSlang, and MINITAB).

5. Statistical Design of Experiments (D.O.E.).

6. Design, model, simulate, and implement innovative algorithms for power and energy battery solutions.

10% of domestic and international travel required.

#LI-DNI

Milwaukee Tool is an equal opportunity employer.