ERS ML Design Optimization Engineer

GM Performance Power Units - Concord, NC Job Summary

GM Performance Power Units (GM PPU) seeks an ERS Simulation ML Engineer to join our team in Concord, NC. This role leverages ML for design optimization, simulation acceleration, and performance analysis of ERS systems (MGU-K, CU-K, ES) using telemetry and physics-based data. Focus on surrogate models to reduce simulation cycles while meeting FIA constraints.

• Design cooling systems for MGU-K, CU-K, and ES, including heat exchangers, interfaces, and fluid routing.
• Perform thermal simulations using STAR-CCM+, ANSYS, or equivalent for CFD/CHT analysis.
• Analyze telemetry data to optimize thermal performance across duty cycles.
• Collaborate with ERS, electronics, mechanical, and integration teams for system packaging.
• Support prototype testing (dyno, track, thermal cycling) and validation.
• Ensure DFM with suppliers for manufacturability and regulatory compliance.
• Document thermal models, results, and trade-offs for review.

• Bachelor's degree in Mechanical or related field;
  Master's preferred.
• 3+ years in thermal management, preferably motor sport or high-power electronics.
• Proficiency in CFD/thermal tools (STAR-CCM+, ANSYS, Sim Scale).
• Strong heat transfer knowledge for electric motors, power electronics, batteries.
• Experience with materials and processes for extreme environments.
• Familiarity with F1 ERS regulations.
• Specific F1 ERS thermal design (MGU-K, CU-K, ES).
• Advanced cooling (oil spray, immersion, phase change).
• Thermal interface optimization and packaging in tight constraints.
• Telemetry analysis and controls integration.

• Innovative problem-solver balancing trade-offs.
• Excellent cross-functional communicator.
• Detail-oriented with continuous improvement mindset.
• Passionate about F1 technology.

You’ll play a pivotal role in ensuring the reliability and performance of a next-generation Formula 1 power unit. Our culture rewards precision, innovation, and the relentless pursuit of performance.