Senior Thermal CFD Simulation Design Engineer - Battery Energy Storage Systems

Senior CFD Simulation Design Engineer BESS

Senior Design Engineer – Thermal CFD Simulation (BESS)

Location: Bengaluru, India
Experience: 8–12 Years
Function: BESS Product Engineering – Simulation & Analysis

About the Role

We are seeking a Senior Design Engineer – Thermal CFD Simulation to lead advanced thermal modeling and CFD simulations for utility?scale and commercial & industrial Battery Energy Storage Systems (BESS).

In this role, you will own the virtual thermal validation of battery systems, enclosures, and cooling architectures and real system development. You will play a critical role in guiding design decisions, reducing physical test iterations, and improving safety, reliability, and performance of stationary storage products.

Key Responsibilities

Thermal Modeling & CFD Simulation

• Develop and execute CFD modelsto analyze: 
  • Battery module and rack thermal behavior
  • Container?level airflow and liquid cooling performance
  • Hot?spot formation and temperature gradients
• Perform steady?state and transient thermal simulations under: 
  • Normal operation
  • High?power and long?duration load profiles
  • Environmental extremes and fault scenarios

Design Support & Optimization

• Support thermal and mechanical teams with simulation?driven design guidance.
• Electro – Mechanical component thermal Analysis 
• Evaluate and compare cooling concepts and layouts using CFD.
• Analyse flow patterns and temperature distributions to optimize cooling, reduce hotspots, and improve system efficiency.
• Optimize airflow, ducting, cooling plate, and cold?plate designs for performance and efficiency.
• Provide actionable recommendations balancing performance, cost, and manufacturability.

Correlation & Validation

• Correlate CFD results with experimental and field test data.
• System level -Model Generation.
• Improve model accuracy through continuous validation.
• Support thermal design verification during FAT, SAT, and commissioning phases.

System?Level Analysis

• Contribute to system?level thermal trade studies for: 
  • Utility?scale containerized BESS
  • Indoor and outdoor C&I installations
• Assess impact of thermal behavior on: 
  • Battery life
  • System derating
  • Safety margins
• Perform steady-state and transient 3D CFD/thermal simulations, focusing on Electrical /Electronic cooling, heat sinks,HVAC and air/liquid cooling systems.

Technical Leadership & Collaboration

• Act as CFD subject?matter expert within the BESS engineering team.
• Mentor junior simulation engineers and review analysis outputs.
• Collaborate with battery, thermal design, mechanical, and system engineering teams.

Required Skills & Experience

Core Technical Skills

• 8–12 years of experience in thermal CFD simulation for batteries, power electronics, or energy systems.
• Strong fundamentals in: 
  • Heat transfer
  • Fluid dynamics
  • Turbulence modeling
• Hands?on expertise with CFD tools such as: 
  • Ansys Fluent / Icepak
  • Star?CCM+
  • SIMcenter
  • Similar commercial CFD platforms
• Experience modeling battery thermal behavior (lumped or detailed approaches).

System & Product Experience

• Experience supporting stationary energy storage or similar large?scale energy systems preferred.
• Understanding of thermal challenges in high?energy, long?duration battery systems.
• Ability to interpret simulation results in the context of real?world operational constraints.

Preferred Qualifications

• Bachelor’s or Master’s degree in Mechanical, Thermal, or Aerospace Engineering.
• Experience with: 
  • CFD automation or scripting
  • Multiphysics simulations (thermal?electrical coupling desirable)
• Familiarity with stationary storage codes and standards (IEC / UL).

Soft Skills

• Strong analytical and modeling mindset.
• Ability to clearly communicate complex simulation results to non?CFD stakeholders.
• Ownership mentality and attention to detail.
• Comfortable working in a fast?paced, product?driven environment.