Staff Engineer - Simulation & Validation

Rehlko • Sheboygan, WI

4d • $98,900 - $125,600 • Hybrid

About The Position

The Staff Engineer, Simulation & Validation, leads thermal and fluid-flow simulation activities and validates analytical results through experimental testing. The role supports development and optimization of engine thermal management systems, power electronics cooling solutions, fuel delivery systems, and exhaust systems. The engineer applies expertise in Computational Fluid Dynamics (CFD), heat transfer, and thermal systems design, collaborating with engineering, testing, manufacturing, and supplier teams to improve product performance, durability, and customer satisfaction.

The position directly influences engine cooling system performance, generator thermal management solutions, power electronics cooling strategies, fuel and exhaust system optimization, product validation methodologies, and future simulation capabilities and engineering best practices. The position is hybrid, with 2–3 days a week at the Sheboygan, Wisconsin work location. Applicants must be authorized to work in the United States without requiring new or transferred visa sponsorship now or in the future.

Rehlko describes its purpose as creating an energy-resilient world for a better future. It offers competitive compensation and benefits, work-life flexibility, recognition and rewards, development and career opportunities, and a safe and inclusive workplace. The stated salary range is $98,900–$125,600. The role contributes to innovative products and technically challenging projects alongside engineering professionals.

Requirements

• Bachelor’s degree in mechanical engineering or a related engineering discipline.
• At least six years of engineering experience in thermal systems, fluid dynamics, simulation, validation, or related technical disciplines; graduate-level research may count toward the experience requirement.
• Demonstrated experience applying Computational Fluid Dynamics (CFD) tools to solve complex engineering problems.
• Strong understanding of heat transfer, thermodynamics, fluid flow, thermal management, cooling systems, and related engineering principles.
• Experience developing simulation models and validating analytical predictions through testing and experimentation.
• Effective technical communication skills, including presenting findings and recommendations to technical and non-technical audiences.
• Authorization to work in the United States without requiring new or transferred visa sponsorship now or in the future.

Nice To Haves

• Master’s degree or PhD in Mechanical Engineering, Thermal Sciences, Fluid Dynamics, Heat Transfer, or a related field.
• Experience with Siemens STAR-CCM+ or similar CFD software.
• Experience supporting engine cooling systems, power generation equipment, power electronics cooling, heat exchangers, or thermal management systems.
• Experience correlating simulation models with laboratory and field validation data.
• Experience authoring technical papers, engineering standards, best practices, or white papers.

Responsibilities

• Lead thermal and fluid-flow simulations to evaluate and optimize cooling system performance using CFD tools, including Siemens STAR-CCM+ and comparable technologies.
• Analyze and optimize engine thermal management systems, including radiators, fans, airflow distribution, cooling packages, and related components.
• Perform simulation and validation activities for fuel delivery, exhaust, and thermal management systems to ensure design and performance targets are achieved.
• Design, evaluate, and optimize heat-transfer solutions for power electronics and related applications.
• Develop analytical methods, processes, and optimization tools to improve thermal system performance, robustness, and cost effectiveness.
• Conduct experimental testing and data analysis to correlate simulation models with physical validation results.
• Partner with product development engineers, laboratory teams, suppliers, and cross-functional stakeholders to solve complex engineering challenges.
• Develop and publish technical reports, engineering standards, validation procedures, best-practice guidelines, and technical documentation.
• Research and evaluate emerging simulation technologies and tools, recommending capabilities that enhance engineering effectiveness and product performance.

Benefits

• Competitive compensation and benefits, including health, vision, and dental coverage.
• 401(k) with Rehlko matching.
• Work-life flexibility.
• Recognition and rewards.
• Development and career opportunities.
• Safe and inclusive workplace.

What This Job Offers

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