Staff Engineer - Simulation & Validation

Rehlko; Town of Mosel (WI); Hybrid; USD 99,000 - 126,000; Full time

Benefits offered by this job

Competitive compensation and benefits

Work-life flexibility

Recognition and rewards

Development and career opportunities

Safe and inclusive workplace

Job summary

Rehlko seeks a Staff Engineer, Simulation & Validation, to lead thermal and fluid flow simulations and validate results with experiments. You will optimize engine cooling, power electronics cooling, and exhaust systems using CFD, heat transfer, and thermal design expertise.

Hybrid work schedule (2–3 days on site) at our Wisconsin facility, with US work authorization. Join a team advancing energy resilience and innovative cooling solutions for diverse applications.

Qualifications

• Bachelor’s degree in mechanical engineering or related discipline.
• 6+ years of engineering experience in thermal systems or CFD.
• CFD experience applying CFD tools to solve problems.
• Strong understanding of heat transfer, thermodynamics, and cooling systems.
• Experience developing simulation models and validating predictions.
• Effective technical communication skills for diverse audiences.

Responsibilities

• Lead thermal and fluid flow simulations to optimize cooling performance.
• Analyze engine cooling systems including radiators and fans.
• Perform simulations and validation for fuel delivery, exhaust, and thermal management.
• Design and optimize heat transfer for power electronics.
• Develop analytical methods and tools to improve performance and cost.
• Conduct experimental testing and correlate results with simulations.
• Collaborate with product teams, suppliers, and labs on engineering challenges.
• Publish technical reports, standards, and validation procedures.
• Evaluate new simulation tools and capabilities for future use.

Skills

CFD expertise

Heat transfer

Thermal management

Engineering communication

Problem solving

Education

Bachelor's in Mechanical Engineering

Tools

Siemens STAR-CCM+

CFD software

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

• 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, thermodynamics, fluid flow, thermal management, cooling systems, and related engineering principles.
• Experience developing simulation models and validating analytical predictions through testing and experimentation.
• Effective technical communication skills, including the ability to present findings and recommendations to technical and non‑technical audiences.

Preferred Qualifications

• Master's degree or PhD in Mechanical Engineering, Thermal Sciences, Fluid Dynamics, Heat Transfer, or a related field.
• Experience with Siemens STAR-CCM+ or similar CFD software.
• Experience supporting engine cooling systems, power generation equipment, power electronics cooling, heat exchangers, or thermal management systems.
• Experience correlating simulation models with laboratory and field validation data.
• Experience authoring technical papers, engineering standards, best practices, or white papers.

The Salary range for this position is $98,900.00-$125,600.00. The specific Salary rate offered to a candidate may be influenced by a variety of factors including the candidate’s experience, their education, and the work location.

About Us

Rehlko proudly offers a rich history steeped in creativity and commitment to our associates and communities, along with competitive benefits and compensation. Our Purpose—Creating an energy resilient world for a better future—and Values: Curiosity, Trust, Pace, and Excellence, are important cultural components that shape the way we work and relate to one another. Learn more about Rehlko at http://www.rehlko.com/who-we-are. In addition to the investment in your development, Rehlko offers a benefits package including a competitive salary, health, vision, dental, 401(k) with Rehlko matching, and more!? Rehlko is an equal opportunity employer that prohibits discrimination and will make decisions regarding employment opportunities, including, but not limited to, hiring, job assignment, compensation, promotion, benefits, training, discipline, and termination, without regard to race, creed, color, ethnicity, religion, sex, pregnancy, childbirth, or related medical conditions, genetic information, age, national origin, citizenship, ancestry, caste, mental or physical disability, marital or familial status, sexual orientation, gender identity or expression, genetic information, political belief or affiliation, union membership status, military status, veteran status, or any other characteristic protected by national, state, local, or other applicable laws.

Rehlko will not discriminate against any qualified associate or applicant with respect to any terms, privileges, or conditions of employment because of a person's physical or mental disability. Rehlko will provide a reasonable accommodation to associates or applicants with disabilities, in accordance with applicable laws. If you have a disability and require an accommodation in the application process or during the course of employment, please contact [e-mail].

Rehlko is an equal opportunity/affirmative action employer. Our Values Curiosity – Seek, learn, share Trust – Go farther together Pace – Focus to go faster Excellence – Find the win every day