Staff Engineer, Thermal CFD & Validation

Rehlko; Sheboygan (WI); Hybrid; USD 99,000 - 126,000; Full time

Benefits offered by this job

Competitive compensation

Health benefits

Work-life flexibility

Professional development opportunities

Job summary

Rehlko in Sheboygan, WI, is seeking a Staff Engineer, Simulation & Validation to lead CFD-based thermal and fluid flow analyses for engine cooling, power electronics cooling, and exhaust systems. You will validate analytical results through experiments, partnering with engineering and supplier teams to optimize performance and durability.

The role emphasizes developing simulation models, advancing validation methodologies, and contributing to future capabilities while working in a hybrid

Qualifications

• Bachelor’s degree in mechanical engineering or related field.
• Minimum of six years in thermal systems, fluid dynamics, simulation or validation.
• Experience applying CFD tools to engineering problems.
• Strong understanding of heat transfer, thermodynamics and cooling systems.
• Experience developing simulation models and validating predictions via testing.
• Effective technical communication skills.

Responsibilities

• Lead thermal and fluid flow simulations to evaluate cooling system performance using CFD tools.
• Analyze and optimize engine thermal management, radiators, fans and airflow.
• Perform simulation and validation for fuel delivery, exhaust and thermal systems.
• Design and optimize heat transfer solutions for power electronics.
• Develop methods and tools to improve thermal system performance and cost effectiveness.
• Conduct experimental testing to correlate simulation with reality.
• Collaborate with product teams, labs and suppliers on engineering challenges.
• Publish technical reports, standards, and validation procedures.
• Explore new simulation technologies to enhance capabilities.

Skills

CFD tools

Heat transfer

Thermal management

Thermodynamics

Fluid dynamics

Simulation & validation

Technical communication

Education

Bachelor’s degree in mechanical engineering

Master’s or PhD preferred

Tools

Siemens STAR-CCM+

Job description

Rehlko in Sheboygan, WI, is seeking a Staff Engineer, Simulation & Validation to lead CFD-based thermal and fluid flow analyses for engine cooling, power electronics cooling, and exhaust systems. You will validate analytical results through experiments, partnering with engineering and supplier teams to optimize performance and durability.

The role emphasizes developing simulation models, advancing validation methodologies, and contributing to future capabilities while working in a hybrid