Thermal Systems CAE Engineer

Thermal Systems CAE Engineer

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Experienced CAE Engineer with robust expertise in Computational Fluid Dynamics (CFD) simulations, dedicated to conducting comprehensive full‑vehicle thermal analysis in support of Ford's vehicle development programs. This role requires an in‑depth understanding of vehicle systems and operations, ensuring seamless collaboration with thermal program engineers, senior leadership, and global teams. The engineer will lead full‑vehicle transient thermal CAE modeling from inception to completion—including data collection, CAD cleanup, meshing, boundary‑condition setup, and post‑processing—while assessing the thermal performance of front‑end cooling systems, under‑hood and body components, and cabin comfort.

The position involves providing technical insights, actionable recommendations, and presenting findings to stakeholders. Continuous improvement of CAE processes and documentation in accordance with Ford’s Thermal Process guidelines are also key responsibilities.

• Lead and execute comprehensive vehicle transient thermal CAE modeling from inception to completion, including CAD data acquisition, model cleanup, meshing, boundary‑condition setup, and post‑processing analysis.
• Conduct and support advanced front‑end CAE analyses, such as 3D airflow simulations, heat‑exchanger and fan sizing, and optimization of heat‑exchanger configurations and front‑end openings.
• Perform CAE evaluations on exterior design proposals from the Studio, supporting the design‑theme selection process and ensuring alignment with overall performance objectives.
• Facilitate collaboration with the Aerodynamics team, balancing thermal design considerations with aerodynamic efficiency to meet vehicle performance goals.
• Work closely with the thermal program team and key stakeholders across the company to deliver optimal thermal environments for all under‑hood and body components.
• Evaluate and optimize the cabin thermal environment, contributing to cabin energy efficiency and human comfort, while complying with comfort standards.
• Interface regularly with the global Ford team—including global thermal teams, CAD, CAE integration, D&R, and other relevant units—to align and integrate global strategies.
• Maintain commitment to high‑quality CAE results and continuously improve processes and methodologies to enhance accuracy, capabilities, and turnaround time within cost‑effective frameworks.
• Provide expert technical recommendations on design optimizations, resolution of engineering issues, and countermeasures informed by in‑depth analysis.
• Present and share insights with thermal program engineers, partners, and leadership, ensuring clear communication of technical results and decisions.
• Document all CAE work and outcomes in accordance with Ford’s Thermal Process guidelines, guaranteeing full traceability and compliance with internal procedures.

• Bachelor’s degree in engineering.
• 3+ years of professional experience in Product Engineering.
• 3+ years of hands‑on expertise in CFD and CAD tools to conduct comprehensive thermal analysis for complete vehicle systems.
• Experience with advanced simulation and modeling software such as Catia, 3DX, Team Center, ANSA, Hypermesh, TAITherm, CCM+, UH3D, OpenFOAM, and EnSight.

• Master of Science in Mechanical or Aeronautical Engineering, or a higher degree, with specialization in fluid mechanics, heat transfer, or HEV battery technologies.
• 5+ years of hands‑on expertise in CFD and CAD tools for comprehensive vehicle thermal analysis.
• Experience working within a globally distributed team environment.

• Immediate medical, dental, vision and prescription drug coverage.
• Flexible family care days, paid parental leave, new‑parent ramp‑up programs, subsidized backup child care and more.
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and…