Formula ERS Thermal Engineer

ERS Thermal Engineer - Onsite

GM Performance Power Units (GM PPU) is seeking an ERS Thermal Engineer with a Formula 1 background to join our engineering team in Concord, NC. This role focuses on thermal management for Motor Generator Unit – e-motor (MGU), Control Unit Kinetic – inverter (CU-K), and Energy Store – battery (ES) systems in F1 power units. The engineer will deliver cooling strategies ensuring performance, reliability, and FIA compliance under extreme conditions.

Key Responsibilities:

• 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.

Required Qualifications:

• 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.

Desirable

Skills:

• 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.

Personal Attributes:

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

Why Join Us

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.