Thermal CAE Engineer - GM Defense

GM Defense; Warren (MI); Hybrid; USD 90,000 - 130,000; Full time

Job summary

GM Defense seeks a Thermal CAE Engineer to build and run thermal models that support virtual analysis for vehicle systems. You will interact with GM defense teams to drive cooling design, assess air flow, and evaluate propulsion and HVAC performance using CFD and FEA tools.

You'll develop novel analysis methods, post-process results, and present findings to ensure system performance meets requirements across multiple programs.

Qualifications

• Bachelor's degree in Mechanical or Electrical Engineering with relevant thermodynamics coursework.
• 5+ years of professional experience in thermal/CFD/FEA environments.
• Experience with lumped-parameter network solvers and CFD methods.
• Proficiency with GT-Suites, MATLAB/Simulink for thermal modeling.
• Experience using CFD tools like ANSA, STAR-CCM+, FLUENT, and NASTRAN/ABAQUS.
• Ability to interpret simulation results for design improvements.

Responsibilities

• Estimate propulsion heat rejection and air flow requirements for cooling systems.
• Size cooling systems and determine capacity for condensers and airflow.
• Perform vehicle-level CFD simulations to guide thermal design.
• Develop simulations for controls, thermal integration, and co-simulation.
• Post-process results and identify performance gaps with recommendations.
• Collaborate with engineering teams and present data clearly to stakeholders.
• Be proactive in creating new analysis methods for defense programs.

Skills

5+ years experience

Thermodynamics

Heat Transfer

Fluid Mechanics

Finite Element Analysis

Lumped-Parameter Models

Propulsion plant modeling

Co-simulation

Controls algorithm development

Open/closed loop modeling

CFD basics

Numerical post-processing

MATLAB/Simulink

STAR-CCM+

GT-Suites

ANSA

FEM/FEA packages (NASTRAN/ABAQUS)

3D CAD data handling

Education

Bachelors in Mechanical or Electrical Engineering

Coursework in Thermodynamics, Heat Transfer, Fluid Mechanics, FEA

Masters or PhD in Mechanical Engineering (preferred)

Tools

ANSA

STAR-CCM+

GT-Suites

MATLAB SIMULINK

FLUENT

EXA-POWERFLOW

Mesh generators

NASTRAN

ABAQUS

Job description

The Role

Thermal CAE Engineer will be responsible for capturing information from a variety of sources inside and outside of GM Defense, building and running analytical models, interpreting results for customers, attending development team meetings, interacting with compartment integration teams, and helping to drive the design that meets internal and external requirements.

Job Description

Thermal CAE Engineer will build, run, and interpret results from various thermal models ranging in complexity from a single component to complex full vehicle systems. The engineer will be an employee within a diverse group of engineers supporting the virtual analysis needs of GM Defense. The engineer will be interacting with the GM thermal analysis groups, performing airflow and thermal simulations of varying complexity. The engineer will drive the design of unique vehicles and systems intended for government applications using virtual analysis tools.

What You’ll Do

• Estimate propulsion heat rejection and determine air flow requirements for cooling system applications.
• Size cooling systems and determine cooling capacity required and air flow requirements for system condensers.
• Evaluate system exteriors with focus on cooling air flow and sealing using Computational Fluid Dynamics (CFD) models (front end cooling, passenger compartment).
• Evaluate propulsion systems cooling and AC system performance using various simulation tools.
• Perform vehicle level CFD simulations to lead the design of the vehicle for thermal management.
• Develop and support novel approaches for analysis in controls, thermal integration, and controls co-sim development.
• Perform finite element and flow analysis on cooling system and plumbing components.
• Proactively develop simulations for new programs based on vehicle content and functional objectives.
• Post-process and interpret simulation results to identify current performance gaps and develop solutions to improve performance.
• Daily use of several commercial CFD codes, solvers and supporting software in Windows, LINUX/UNIX and HPC environment. These include ANSA, STAR-CCM+, GT-Suites, MATLAB SIMULINK, and other internal codes.
• Interface and collaborate with Studio and Engineering Teams, present numerical and visual data, and recommendations effectively, to ensure component and system level performance requirements are achieved.
• Fully engage in vehicle development activity and proactively take ownership of simulation activity to best guide the design team.
• Be willing to question the status quo and work to develop new methods and tools to streamline the defense toolkit in the thermal space.

Your Skills & Abilities (Required Qualifications)

• Bachelor’s degree in Mechanical or Electrical Engineering with coursework in Thermodynamics, Heat Transfer, Fluid Mechanics and Finite Element Analysis.
• 5+ years of professional experience.
• Experience and coursework in Lumped-Parameter Network Solvers, CFD methodology and application.
• Theoretical background in propulsion plant modeling for controls algorithm development in GT‑suites and MATLAB/Simulink as inputs to thermal model.
• Experience with computer tools, 3D CAD files, CAE methods and Experimental Data.
• Familiarity with Aerodynamic and Climatic Wind Tunnel testing, measurement techniques and data systems.
• Experience using commercial CFD solvers such as FLUENT, STAR-CCM+, EXA-POWERFLOW, Mesh generators such as ANSA, HYPERWORKS and FEA Codes such as NASTRAN and ABAQUS.

What Will Give You A Competitive Edge (Preferred Qualifications)

• Masters or Ph.D. in Mechanical Engineering with focus on Thermal Sciences.
• Mathematical modeling and analysis of various subsystems of both conventional and electric vehicle powertrain using state-of-the-art analytical tools, including STAR-CCM+, MATLAB/Simulink and co-sim environments.
• Modeling, simulation, and validation of open and closed loop system models in desktop simulation and HIL hardware.
• Adapt System models (e.g. MATLAB/Simulink) for real time execution in a Model‑in‑loop, software‑in‑loop system.
• Experience in design/release of automotive thermal systems.
• DFSS training, Green Belt or beyond.
• Comfortable with an ever‑changing environment, flexible in skillset, willing to learn and can handle ambiguous assignments.

Location & Sponsorship

GM does not provide immigration-related sponsorship for this role. This role is categorized as hybrid; the selected candidate is expected to report to a specific location at least 3 times a week or other frequency dictated by their manager. This job may be eligible for relocation benefits. The position is subject to export control restrictions and requires the successful candidate to be either a U.S. Person (U.S. citizen, U.S. permanent resident, asylee or refugee) or a non-U.S. Person who is eligible to obtain any required export control authorization.

Benefits Overview

From day one, we support your well‑being at work and at home so you can focus on realizing your ambitions. Learn how we support a rewarding career that rewards you personally by visiting Total Rewards resources.

Non-Discrimination and Equal Employment Opportunities (U.S.)

General Motors is committed to being a workplace that is not only free of unlawful discrimination, but one that genuinely fosters inclusion and belonging. All employment decisions are made on a non‑discriminatory basis without regard to sex, race, color, national origin, citizenship status, religion, age, disability, pregnancy or maternity status, sexual orientation, gender identity, status as a veteran or protected veteran, or any other similarly protected status in accordance with federal, state and local laws.

Accommodations

General Motors offers opportunities to all job seekers, including individuals with disabilities. If you need a reasonable accommodation to assist with your job search or application for employment, email us or call us at 1-800-865-7580. In your email, please include a description of the specific accommodation you are requesting as well as the job title and requisition number of the position for which you are applying.