ERS ML Design Optimization Engineer

GM Performance Power Units • Concord, NC

2d • Onsite

About The Position

GM Performance Power Units (GM PPU) seeks an ERS Simulation ML Engineer to join our team in Concord, NC. This role leverages ML for design optimization, simulation acceleration, and performance analysis of ERS systems (MGU-K, CU-K, ES) using telemetry and physics-based data. Focus on surrogate models to reduce sim cycles while meeting FIA constraints.

Requirements

• Bachelor's degree in Mechanical or related field; Master's preferred.
• 3+ years in thermal management, preferably motorsport or high-power electronics.
• Proficiency in CFD/thermal tools (STAR-CCM+, ANSYS, SimScale).
• Strong heat transfer knowledge for electric motors, power electronics, batteries.
• Experience with materials and processes for extreme environments.
• Familiarity with F1 ERS regulations.

Nice To Haves

• Specific F1 ERS thermal design (MGU-K, CU-K, ES).
• Advanced cooling (oil spray, immersion, phase change).
• Thermal interface optimization and packaging in tight constraints.
• Telemetry analysis and controls integration.

Responsibilities

• Design cooling systems for MGU-K, CU-K, and ES, including heat exchangers, interfaces, and fluid routing.
• Perform thermal simulations using STAR-CCM+, ANSYS, or equivalent for CFD/CHT analysis.
• Analyze telemetry data to optimize thermal performance across duty cycles.
• Collaborate with ERS, electronics, mechanical, and integration teams for system packaging.
• Support prototype testing (dyno, track, thermal cycling) and validation.
• Ensure DFM with suppliers for manufacturability and regulatory compliance.
• Document thermal models, results, and trade-offs for review.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level