Thermal Systems Engineer (cooling, HVAC)

The Mid-Level Thermal Systems Engineer is responsible for the design, analysis, and integration of vehicle thermal systems, including engine/battery cooling and HVAC systems. This position focuses on system-level performance, packaging, and development activities across vehicle programs. The engineer collaborates with cross-functional teams to ensure the thermal systems meet functional, safety, and efficiency targets throughout the product development cycle.

Key Responsibilities:

• Design and develop cooling and HVAC systems including heat exchangers, fans, pumps, lines, actuators, and control logic.

• Conduct performance sizing and system simulations using 1D tools (e.g., GT-SUITE, AMESim) and collaborate with CAE analysts.

• Lead component selection and define system architecture for powertrain and cabin thermal systems.

• Ensure integration of thermal systems within vehicle packaging constraints in coordination with CAD and packaging teams.

• Develop and maintain system specifications, DFMEAs, and validation plans (DVP&R).

• Support prototype builds, test plan execution, and analysis of thermal performance data.

• Interface with suppliers for component development, quality checks, and validation requirements.

• Provide engineering support for manufacturing, assembly, and service-related considerations.

Key Focus Areas:

• Thermal System Architecture Development
  (System layout, flow routing, loop management for battery, inverter, motor, engine, HVAC)

• Thermal Load Estimation and Performance Analysis
  (Heat rejection calculations, thermal balance, airflow and refrigerant flow analysis)

• HVAC and Cooling System Integration
  (Optimization of packaging, routing, and component layout for performance and serviceability)

• 1D Thermal Simulation & Data Interpretation
  (Use of simulation tools for performance prediction and component sizing)

• Control Strategy Collaboration
  (Work with software teams to develop logic for fans, valves, and HVAC actuators)

• Prototyping and Validation Support
  (Sensor placement, test planning, data acquisition, failure analysis)

Qualifications:

• Bachelor’s degree in Mechanical, Thermal, or Automotive Engineering (Master’s preferred).

• 3–7 years of experience in thermal systems engineering in automotive or related field.

• Strong understanding of heat transfer, thermodynamics, and fluid mechanics.

• Proficient with CAD software (CATIA, NX, SolidWorks) and 1D simulation tools.

• Experience with product development lifecycle, DFMEA, and validation protocols.

Preferred Skills:

• Familiarity with electrified powertrain thermal systems (battery, inverter, motor cooling).

• Working knowledge of HVAC refrigerant cycle and related components (compressors, evaporators, TXVs, etc.).

• Hands-on experience with vehicle testing and thermal instrumentation.

• Exposure to thermal system controls, diagnostics, and software/hardware integration.

• Effective communication skills for working with suppliers, test teams, and cross-functional departments.