Lead Thermal CFD Engineer - Automotive Electronics

Lead Thermal CFD Engineer – Automotive Electronics

As a Lead Engineer, you will play a critical role in simulating, analysing, and optimising the thermal performance of automotive electronic systems using advanced CFD tools. You will bridge virtual simulations with physical validation through strong Test–CAE correlation, ensuring accurate predictive modelling.

You will work across cross-functional teams to improve design robustness, enhance thermal reliability, and establish standardised simulation methodologies.

Technical Leadership

• Act as Subject Matter Expert (SME) for CFD-based thermal analysis
• Provide technical guidance and mentorship to junior engineers
• Define and standardise best practices in modelling, meshing, and simulation workflows

Model Development & Simulation

• Develop high-fidelity CFD models from complex CAD assemblies
• Perform geometry clean-up and mesh generation using ANSA
• Execute:  
  • Surface and volume meshing (tetrahedral, polyhedral, prism layers)
  • Steady-state and transient Conjugate Heat Transfer (CHT) simulations

Physics & Boundary Conditions

• Define material properties, thermal interfaces, and contact resistances
• Model advanced physics including: 
  • Solar radiation loads
  • Surface-to-surface radiation
  • Natural and forced convection

Thermal Analysis

• Simulate extreme operating conditions such as: 
  • High solar loading and cabin soak
  • Maximum air conditioning scenarios
  • Sub-zero cold start conditions
• Identify hotspots, airflow issues, and recirculation zones

Validation & Quality Control

• Lead Test–CAE correlation activities
• Review:  
  • CAD clean-up quality
  • Mesh quality metrics
  • Solver configurations and outputs
• Ensure high accuracy and reliability of simulation results

Collaboration & Reporting

• Present insights and recommendations to cross-functional teams
• Support design improvements for thermal performance optimisation

Education

• M.E. / M.Tech in Mechanical Engineering, Thermal Engineering, or related field

Experience

• 8–12 years of experience in CFD-based thermal analysis
• Strong experience in automotive electronics thermal management preferred

Technical Skills

• Expertise in: 
  • ANSA (pre-processing and meshing)
  • Ansys Fluent (solver setup and analysis)
• Strong understanding of: 
  • Conjugate Heat Transfer (CHT)
  • Radiation modelling (S2S, solar load)
  • Fluid-solid interaction and thermal interfaces

Domain Knowledge

• Experience with: 
  • Automotive Instrument Panels (IP)
  • Centre consoles
  • Electronic control modules (ECUs, infotainment, clusters)

Soft Skills

• Strong analytical and problem-solving abilities
• Effective communication and stakeholder management
• Ability to mentor and lead technical teams

Experience Level

Senior Level