Staff Engineer - Simulation & Validation

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

Why Work at Rehlko

Our work is guided by our purpose: creating an energy-resilient world for a better future. This purpose embodies the legacy we bring, with more than 100 years as the global leader in energy resilience, delivering solutions critical to sustain and improve life.

Our teams have the opportunity to provide a critical resource - energy - that ensures safety, security, and independence for people around the world. Our team members are focused on pushing boundaries, continuing to innovate in an ever-changing landscape, and keeping up with the pace required to create solutions for today's world demands.

Our product range includes engines, generators, power conversion, UPS systems, EV components and electrification solutions, microgrid controls and management, and clean energy solutions that serve a broad spectrum of OEM, residential, industrial, and commercial customers. At Rehlko, you have the freedom to identify, create, and deliver solutions - large and small - that help people and communities thrive in the moments that matter.

At Rehlko, our team members are the essential energy that powers our organization's success. We are committed to fostering a safe and sustainable work environment where safety is everyone's responsibility. We empower every team member to actively participate in our Zero Is Possible safety culture by encouraging open communication, proactively reporting hazards, following protocols, and suggesting improvements. Join us in creating an energy resilient world for a better future!

What We Offer

At Rehlko, our Total Rewards programs are designed to accelerate growth, energize performance, and support a culture of inclusion at every stage of life and work. We offer total rewards that are easily understood, recognize results, enable career mobility, and reflect our commitment to valuing diverse needs in a fast-moving world. We provide:

• Competitive compensation and benefits
• Work-life flexibility
• Recognition and rewards
• Development and career opportunities
• A safe and inclusive workplace

Why You Will Love this Job

The Staff Engineer, Simulation & Validation, is responsible for leading thermal and fluid flow simulation activities and validating analytical results through experimental testing. This role supports the development and optimization of engine thermal management systems, power electronics cooling solutions, fuel delivery systems, and exhaust systems.

The ideal candidate will bring expertise in Computational Fluid Dynamics (CFD), heat transfer, and thermal systems design while collaborating across engineering, testing, manufacturing, and supplier teams to improve product performance, durability, and customer satisfaction. This position directly influences engine cooling system performance , generator thermal management solutions , power electronics cooling strategies , fuel and exhaust system optimization , product validation methodologies , and future simulation capabilities and engineering best practices.

Work mode: Hybrid-2-3 days a week

Work Location: N7650 County Rd LS, Sheboygan, WI, 53083.

Applicants must be authorized to work in the US without requiring new or transfer visa sponsorship now or in the future.

Key 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.

Required 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. Graduate-level research may be considered toward experience requirements.
• Demonstrated experience applying Computational Fluid Dynamics (CFD) tools to solve complex engineering problems.
• Strong understanding of heat transfer, thermod