Sr. Thermal Design Engineer

IEA; Kenosha (WI); On-site; USD 110,000 - 170,000; Full time

Job summary

IEA in Wisconsin is seeking a Senior Thermal Design Engineer to lead heat transfer design and development of heat transfer equipment and products. You will perform heat transfer calculations, review lab data, and drive modeling, prototype testing, and cost assessment across projects.

The role requires a Master’s in mechanical/thermal engineering and 10 years in heat exchanger design, with proficiency in Kuli, FEA, and CFD. Expect domestic and international travel as needed.

Qualifications

• Master’s degree in mechanical, thermal, or energy engineering.
• 10 years of experience in heat exchanger design and manufacturing.
• Proven NPD experience and budgeting awareness.
• Proficient with CAE tools (Kuli, FEA, CFD).
• Ability to communicate effectively in writing and speaking.

Responsibilities

• Perform heat transfer calculations and predictions.
• Review laboratory test data and translate into design actions.
• Model heat transfer, conduct programming, and develop applications (Kuli).
• Plan prototypes, test, and assess prototype/process costs.
• Lead product validation, certification assessment, and customer/partner technical support.
• Develop standards, manage projects, and schedule activities.
• Utilize CFD/FEA in design and development.

Skills

Heat transfer theory

Radiator design

Materials knowledge

CAe tools

FEA CFD

Project management

Effective communication

Education

Master's degree in mechanical/thermal/energy engineering

Tools

Kuli

FEA

CFD

Job description

Job Summary: The Senior Thermal Design Engineer: Responsible for product design and development of heat transfer equipment and products. Tasks include Heat Transfer Calculations/Predicting. Laboratory test data review, interpretation, and action (heat transfer, materials analysis, and structural). Heat Transfer Modeling, programming, and application development with Kuli. Prototype planning, prototype testing, and prototype/process/program cost assessment. Product validation and/or certification assessment. Customer Technical Support, Supplier and Partner Technical Support and Interdepartmental Technical Support. Concept development, standards development (material, design, and test focus). Responsible for project/program scheduling, prototype building, computational fluid dynamics awareness, and finite element analysis use. Qualify all new products and maintain standards on existing products.Essential Duties and Responsibilities include the following with other duties assigned as necessary:Heat Transfer Calculations/PredictingLaboratory Test Data Review, Interpretation and Action (heat transfer, materials analysis and some structural)Heat Transfer Modeling, Programming and Application Development with KuliPrototype PlanningPrototype TestingPrototype / process / program cost assessment.Product Validation and/or Certification AssessmentCustomer Technical SupportSupplier and Partner Technical SupportConcept DevelopmentInterdepartmental Technical SupportStandards Development (material, design, and test focus)Project / Program SchedulingPrototype BuildingComputational Fluid Dynamics AwarenessFinite Element Analysis UseMaintains a positive, discrimination-free workplace for all employees.Qualifies all new products and maintains standards on existing products.Physical Demands:Maximum lifting requirement (pounds): 10 (seldom).Maximum moving requirement (pounds): 25 (seldom).Maintaining physical condition necessary for the following: Frequent standing, walking, or sitting; infrequent kneeling, crouching, stooping, squatting, twisting upper body, or climbing.Working at heights off the ground up to 10 feet (seldom).Vision requirements: Close, distance, and peripheral vision; depth perception.Travel: Domestic and international travel—1-5 days (rarely), 5-15+ days (rarely).Work Environment:Work location(s): Office; metal fabrication/assembly shop; field visits to customer/rep locations including domestic/international travel.Unlikely exposure to fumes, airborne particles, wet/humid (non-weather) conditions, toxic/caustic chemicals, moving mechanical parts/equipment, inclement weather conditions.Personal protective equipment requirement: Safety glasses with side shields when in shop areas. Safety toe shoes when working/visiting shop environments. Additional equipment as per job site/length of stay requirements.Position Requirements:Key skills, abilities, and knowledge:Extensive knowledge of heat transfer theory, radiator design, materials, assembly, and operating characteristics.Familiarity with New Product Development CyclesAbility to work on technology programs with consideration for overall budget and timing.Knowledge of predictive software - Kuli specificallyAbility to communicate effectively orally and in writing.Ability to conduct research (problem identification, data collection and analysis, solution formulation, testing and evaluation).Skill in dealing with others including Engendren employees, suppliers, and end users.Ability to plan, organize and direct multiple projects simultaneously.Familiarity with CAE tools - Kuli, FEA and CFDAbility to build and maintain positive professional relationships (in person/phone/e-mail).Experiential:Master’s degree in mechanical, Thermal, Energy Engineering, or a closely related discipline.Ten years of experience in heat exchanger design, calculations, and manufacturingMin of seven years of product technology developmentCertificates, Licenses, etc.:Driver’s license; passport (for foreign travel as necessary).IEA is an equal employment opportunity employer. Our policy is to provide equal employment opportunities to all qualified persons, without regard to race, sex, color, disability, national origin, age, religion, union affiliation, sexual orientation, veteran status, citizenship, gender identity, and/or expression, or other status protected by law. If you require any reasonable adjustments to accommodate health condition or disability, please let us know. Your journey with us matters.