Thermal Engineer

Job Title:

Thermal Simulation Engineer

Job Description

This role focuses on developing and applying advanced thermal and structural simulation models to optimize product designs and manufacturing processes, with a particular emphasis on current‑carrying products such as connectors, busbars, and cable assemblies. You will work closely with design, manufacturing, and testing teams to validate simulations, solve complex thermo‑mechanical issues, and drive data‑driven improvements in product performance, reliability, and cost efficiency from concept through production.

Responsibilities

+ Lead the development and implementation of complex thermal simulation models to optimize product designs and manufacturing processes, especially for current‑carrying products including connectors, busbars, and cable assemblies.

+ Perform detailed calculations and simulations on temperature distribution across systems to assess thermal performance, heat transfer, and reliability.

+ Conduct thermo‑mechanical and structural simulations to support design optimization, material selection, and validation throughout the product lifecycle from concept to production.

+ Simplify complex CAD geometries to enable efficient and accurate structural and thermal simulation analyses.

+ Apply in‑depth knowledge of mechanical design, conductive and convective heat transfer, and fluid flow mechanics to build robust simulation models.

+ Collaborate with design, manufacturing, and testing teams to correlate FEA results with physical test data and refine models and designs accordingly.

+ Use Design of Experiments (DOE) and optimization techniques to systematically improve designs and processes based on simulation outcomes.

+ Direct cross‑functional teams to address and resolve intricate design and manufacturing issues identified through simulations and testing.

+ Analyze complex simulation results to identify performance gaps and improvement opportunities, and drive design or process changes to address them.

+ Ensure simulation models are maintained, updated, and enhanced to preserve accuracy, relevance, and alignment with evolving product and process requirements.

+ Validate concept designs using simulation techniques to determine design robustness and confirm that critical functional requirements are met.

+ Deploy FEA techniques using implicit and explicit approaches with tools such as Ansys Workbench, LS‑DYNA, Hyper Mesh, Simufact, Moldex3D, OptiSLang, Icepak, Maxwell, and Ansys HFSS.

+ Translate real‑world engineering problems into appropriate finite element analysis (FEA) models, interpret analysis results, and select optimal solutions, including linear and non‑linear analyses under multiple physics domains.

+ Monitor and evaluate simulation software capabilities and industry trends, recommending improvements or new tools to enhance analysis workflows.

+ Collaborate closely with design and validation teams to enhance design optimization and ensure simulation insights are integrated into product development.

+ Consider the financial impact of design and process decisions, using simulation results to support cost‑effective and value‑driven solutions.

+ Apply knowledge of associated manufacturing processes such as molding, stamping, plating, crimping, and assembly to build realistic models and interpret results.

+ Incorporate understanding of soldering, crimping, and welding technologies into simulation and design recommendations.

+ Utilize expertise in CAE tools, optimization techniques, and testing methods to correlate test and simulation data and continuously improve model fidelity.

+ Implement LEAN, Six Sigma, and Kaizen techniques in live projects to streamline workflows, reduce waste, and improve quality.

+ Support technical paper publications and patent applications by generating high‑quality simulation data, analysis, and documentation.

Essential Skills

+ Bachelor's degree (BE/B.Tech) in Mechanical or Electrical Engineering.

+ 3-5 years of industry experience in thermal, structural, or simulation engineering.

+ Strong expertise in Ansys Workbench for FEA‑based thermal and structural simulations.

+ Hands‑on experience with thermal simulation of…