Sr Engineer Systems - Thermal​/CFD

Overview

Harley-Davidson Motor Company is seeking a Sr Engineer Systems
- Thermal/CFD for the Product Development Center (PDC) in Wauwatosa, WI. This onsite, part-time role supports vehicle aerodynamics, thermal comfort, and powertrain development (ICE/EV) through 3-D CFD simulation and analysis. The position collaborates with motorcycle project teams, design studio, test labs, and external partners to deliver innovative solutions for current production issues and future product plan projects.

The Senior Systems Engineer
- Thermal/CFD is a full-time onsite position reporting to the System/Component Simulation Engineering Manager. The role provides 3-D CFD simulation and analysis to support vehicle aerodynamics, thermal comfort, and powertrain development, aligning with cross-functional strategies within product development.

• Retrieve, prepare, and clean CAD parts for CFD volume meshing
• Collaborate with internal customers to ensure proper boundary conditions are applied
• Work with Powertrain, Electrical, Mechanical, and Reliability engineers to develop simulation cases and physical tests in parallel to validate and refine 3-D/1-D models
• Develop 3-D/1-D CFD/CAE models to analyze thermodynamics, fluid flow, and heat transfer (lubrication, cooling, air and other means)
• Develop 3-D/1-D thermal models of heat conduction, convection, and radiation to support thermal design decisions and their impact on vehicle components (rider/passenger)
• Model components such as powertrain, battery cases, motors, metals, non-metals, gap fillers, conduction interfaces, coatings, and battery cells
• Develop 3-D/1-D thermal models for power electronics and motor cooling, including motor windings and rotor interior
• Develop 3-D/1-D thermal convection models for understanding ICE/EV energy balance
• Analyze 3-D/1-D models to identify opportunities for overall vehicle/system improvements (pressure loss, heat transfer, energy balance, flow and drag)
• Communicate across software tools to quantify or optimize vehicle/sub-system performance (Star-CCM+, GT-Power, Sculptor, Mode Frontier, Simulink)
• Interpret analysis results in relation to lab testing and translate findings into practical design suggestions
• Validate/correlate results with real-world data and drive model improvements for methods development
• Generate high-level engineering reports and present CFD/CAE results and conclusions to motorcycle project teams

Bachelor’s Degree Required

Position requires a bachelor’s degree in one of the following disciplines:
Mechanical Engineering (Fluids, Heat Transfer, or Combustion emphasis), Aerospace/Aeronautical Engineering, or Applied Physics. Master’s degree or PhD with specialization in CFD is preferred.

The successful candidate will have a minimum of 5 years of related experience, including:

• Demonstrated history of 3-D CFD simulations in battery enclosure heat transfer, ICE heat transfer, powertrain applications, vehicle aerodynamics, and thermal comfort
• Strong understanding of thermodynamics, fluid flow, heat transfer, and combustion
• Experience with CFD tools (e.g., Star-CCM+, Converge, GT-Power, mode Frontier, Sculptor, Tai Therm, Simulink, Optistruct)
• Experience with data sets and CFD correlation (Powertrain, Dyno, Vehicle, Wind tunnel)
• Experience in parallel computations, parametric modeling, and design optimization
• Proficiency in programming with MATLAB, Python, Java, and related tools
• Familiarity with Creo and CFD mesh repair techniques
• Excellent verbal and written communication skills
• Strong interpersonal and problem-solving abilities
• Demonstrated technical problem-solving capability

The pay range shown represents the national average for this role. Pay may vary by location and experience.

We offer an inclusive compensation package for all full-time salaried employees including annual bonuses, health insurance, 401(k), onsite fitness centers and employee stores, product discounts, and more. Learn more about Harley-Davidson here.

Applicants must be authorized to work in the United States. Direct Reports:
Yes. Travel: 0-10%. Pay Range: $93,400 - $145,000. Visa Sponsorship:
Not eligible. Relocation:
Domestic relocation assistance available within the posted country.