The Director – Powertrain Airflow & Thermal Efficiency is responsible for leading the engineering strategy, development, and optimization of air induction, exhaust flow, and thermal management systems across internal combustion, hybrid, and electrified powertrains. This role directs cross-functional teams to enhance volumetric efficiency, combustion performance, and overall thermal energy utilization. The director plays a critical role in improving fuel economy, emissions, power density, and component durability through advanced fluid dynamics, heat exchange, and system integration strategies.
Define and lead the roadmap for airflow and thermal efficiency technologies across multiple propulsion architectures.
Develop and oversee strategies for optimizing air handling systems (intake, charge air cooling, exhaust) and underhood thermal environments.
Drive innovation in combustion air path design, flow control, and heat recovery to support regulatory and performance targets.
Lead design, simulation, and validation of components and systems including:
Intake manifolds, air filters, ducting
Turbo/supercharging interfaces
Exhaust manifolds and thermal shielding
Charge air coolers, EGR systems, and thermal bypass valves
Ensure effective integration with engine combustion systems, aftertreatment, hybrid motors, and power electronics cooling loops.
Oversee modeling and development of thermal energy flows from combustion to underhood and drivetrain components.
Optimize cooling strategies and energy recovery across radiators, oil coolers, intercoolers, and thermal valves.
Implement tools and methods for transient thermal analysis and thermodynamic cycle optimization.
Lead advanced development programs and production implementation of airflow and thermal systems.
Collaborate with engine, hybrid, vehicle packaging, calibration, and controls teams to deliver fully integrated thermal solutions.
Engage with suppliers to ensure component quality, manufacturability, and performance compliance.
Build and lead a global team of airflow, combustion, and thermal systems engineers.
Establish best practices in CFD, CAE, thermodynamic modeling, and DVP&R for airflow/thermal systems.
Mentor staff and drive continuous improvement in analysis, design, and product integration.
Powertrain airflow management and thermal energy optimization
Volumetric efficiency, charge motion, and exhaust flow control
Advanced cooling, heat shielding, and energy recovery strategies
Thermofluid modeling, CFD, and thermal management simulation
Integration with electrified propulsion and emissions reduction technologies
Cross-functional design collaboration and component standardization
Bachelor’s degree in Mechanical, Automotive, or Aerospace Engineering required
Master’s or PhD in Thermodynamics, Fluid Dynamics, or Powertrain Systems strongly preferred
PE License, Six Sigma Black Belt, or PMP certification a plus
Thermal systems or CFD-specific credentials beneficial
12+ years in powertrain airflow, cooling systems, or thermal engineering
5+ years in an engineering leadership or director-level position
Proven experience delivering advanced airflow or thermal systems for ICE, hybrid, or EV platforms
Proficiency with CFD tools (e.g., STAR-CCM+, Fluent), thermal modeling (GT-SUITE, Flowmaster), and CAE software
Deep understanding of thermodynamics, heat transfer, and combustion air systems
Familiarity with underhood thermal integration, emissions controls, and hybrid cooling circuits
Strategic thinker with strong technical acumen and business alignment
Exceptional cross-functional leadership and communication abilities
Skilled at building high-performance technical teams and guiding innovation