The Senior Thermal Systems Engineer leads the design, integration, and validation of complete thermal management and HVAC systems across vehicle programs. This role involves ownership of system architecture, performance optimization, supplier coordination, and cross-functional leadership. The engineer ensures that thermal systems meet targets for efficiency, comfort, durability, manufacturability, and regulatory compliance across internal combustion, hybrid, and electric vehicle platforms.
Lead the development of cooling loops (powertrain, battery, inverter, motor) and HVAC systems from concept to production.
Define system architecture, including heat exchanger networks, valves, pumps, actuators, and control strategies.
Conduct advanced thermal performance analysis using simulation tools (e.g., GT-SUITE, AMESim).
Ensure compliance with performance, NVH, safety, and regulatory requirements.
Guide CAD and packaging teams in optimal layout and integration of thermal components.
Define and review DVP&R, DFMEA, and interface control documents (ICDs).
Lead design reviews and technical discussions with suppliers and internal stakeholders.
Support prototype build, instrumentation planning, and thermal system testing (climatic chambers, road testing).
Mentor junior engineers and provide technical leadership in cross-functional teams.
Advanced Thermal Management System Design
(Multiple loop integration for ICE, hybrid, and EV platforms)
System-Level Performance Optimization
(Energy efficiency, thermal comfort, rapid warm-up/cool-down, parasitic load reduction)
Control Strategy Definition and Validation
(Integration of thermal controls with ECU/software teams for smart energy management)
HVAC System Architecture and Comfort Tuning
(Cabin climate control performance, occupant comfort, defrost/demist optimization)
Simulation and Predictive Modeling
(Thermal transient modeling, system sizing, refrigerant cycle analysis)
Supplier and Cross-Functional Coordination
(Interface with electronics, body, software, powertrain, and chassis teams)
Compliance and Innovation
(Emissions, refrigerant regulation, heat pump and waste heat recovery integration)
Bachelor’s or Master’s degree in Mechanical, Automotive, or Thermal Engineering.
7+ years of experience in automotive thermal system design and development.
Deep knowledge of heat transfer, HVAC systems, fluid dynamics, and thermodynamics.
Proficient with CAD tools (CATIA, NX), simulation software (GT-SUITE, Flowmaster), and control logic understanding.
Proven track record of launching thermal systems in production vehicles.
Experience with EV and hybrid vehicle thermal systems.
Knowledge of refrigerant alternatives and heat pump technologies.
Familiarity with vehicle validation standards (SAE, ISO, etc.).
Strong project leadership, supplier management, and mentoring capabilities.
Cross-cultural communication experience with global engineering teams.