Job Purpose (Significance of the Role & Objectives) We are looking for a Thermal Systems Engineer – Vehicle & Battery with strong experience in CFD-based thermal analysis for EV battery packs and powertrain systems. The role involves end-to-end ownership of thermal simulations, cooling system design, vehicle-level integration, and correlation with test data. The ideal candidate has hands-on experience working on at least one running vehicle or battery pack program. Key Responsibilities and Deliverables 1. Simulation & Analysis (50%) - Perform CFD-based thermal simulations using ANSYS Fluent / Star-CCM+ (mandatory). - Battery pack thermal analysis at cell-level and module-level, including steady-state and transient cases. - Thermal simulation of inverter and motor cooling systems. - Under-hood and under-body airflow and thermal management studies. - Analyze Joule heating and electrical losses in: - Busbars, tabs, connectors - High-current transient operating conditions - Support thermal runaway mitigation, venting, and safety studies (good to have). - Prepare simulation reports with clear design recommendations. 2. Design & Packaging (30%) - Design and optimize cooling plates, ducts, and flow paths. - Perform fan and pump sizing based on thermal and hydraulic requirements. - Package thermal systems at the vehicle level, considering space, manufacturability, and serviceability. - Work closely with CAD teams using SolidWorks / CATIA / NX to implement thermal solutions. - Support design trade-offs between performance, cost, weight, and packaging constraints. 3. Execution & Validation (20%) - Define and support sensor placement (NTCs, RTDs,



thermocouples) for validation. - Correlate CFD results with vehicle, dyno, and bench test data. - Coordinate with vendors for radiators, pumps, hoses, and thermal components. - Support vehicle testing, dyno testing, and on-road validation activities. - Troubleshoot thermal issues observed during testing and production trials. Desired Qualifications: Required Qualifications, Knowledge, and Experience Required Qualifications - Bachelor’s or Master’s degree in Mechanical, Automotive, Electrical, or Thermal Engineering - 3–7 years of relevant industry experience - Background in EVs, automotive systems, or power electronics - Direct involvement in at least one running vehicle program or battery pack Knowledge and Experience - Strong expertise in ANSYS Fluent or Star-CCM+ (non-negotiable) - Working experience with Icepak (robust plus) - Practical understanding of: - Battery thermal management systems - Motor and inverter cooling - Vehicle-level airflow and heat rejection - CAD experience using SolidWorks / CATIA / NX - Basic proficiency in MATLAB for data analysis and post-processing - Familiarity with thermal testing, validation, and correlation methods Key Competencies - Ability to work effectively with incomplete or evolving data - Strong engineering judgment beyond simulation results - Comfortable with fast iteration cycles and startup-style execution - Hands-on mindset with shop-floor and test-track interaction - Clear communication with cross-functional teams (design, testing, vendors) - Problem-solving approach focused on real-world performance, not just “CFD says OK”

📌 Thermal Systems Engineer – Vehicle & Battery (Bengaluru)
🏢 Pravaig
📍 Bengaluru