Thermal Systems CAE Engineer

Ford•Dearborn, MI

About The Position

Experienced CAE Engineer with a robust expertise in Computational Fluid Dynamics (CFD) simulations, dedicated to conducting comprehensive full-vehicle thermal analysis in support of Ford's vehicle development programs. Bachelor's degree in engineering 3+ years of professional experience in Product Engineering is required 3+ years of hands-on expertise in utilizing Computational Fluid Dynamics (CFD) and Computer-Aided Design (CAD) tools to conduct comprehensive thermal analysis for complete vehicle systems. 3+ years of experience using advanced simulation and modeling software tools such as Catia/3DX/TeamCenter, ANSA/Hypermesh, TAITherm, CCM+/UH3D/OpenFOAM, and EnSight, demonstrating an ability to leverage these tools to deliver detailed, high-fidelity thermal and fluid flow analyses, particularly in the context of automotive or aerospace applications. Master of Science in Mechanical or Aeronautical Engineering, or a higher degree, with a specialization in fluid mechanics, heat transfer, or HEV battery technologies. 5+ years of hands-on expertise in utilizing Computational Fluid Dynamics (CFD) and Computer-Aided Design (CAD) tools to conduct comprehensive thermal analysis for complete vehicle systems. Experience working within a globally distributed team environment. Lead and execute comprehensive vehicle transient thermal CAE (Computer-Aided Engineering) modeling from inception to completion, including CAD data acquisition, model cleanup, meshing, boundary condition setup, and post-processing analysis. Conduct and support advanced front-end CAE analyses, such as 3D airflow simulations, heat exchanger and fan sizing, as well as optimizing heat exchanger configurations and front-end openings. Collaborate on optimizing front-end openings and grille designs to achieve vehicle airflow and performance targets throughout various stages of vehicle development. Perform CAE evaluations on exterior design proposals from the Studio, providing support for the design theme selection process, and ensuring alignment with overall performance objectives during the studio design phase. Facilitate seamless collaboration with the Aerodynamics team, ensuring that thermal design considerations are balanced and optimized in conjunction with aerodynamic efficiency to meet overarching vehicle performance goals. Work closely with the thermal program team and key stakeholders across the company, ensuring the delivery of optimal thermal environments for all under-hood and body components throughout the development lifecycle. Evaluate and optimize the cabin thermal environment, contributing to the enhancement of cabin thermal energy efficiency and human comfort, while ensuring compliance with comfort standards and performance benchmarks. Interface regularly with the global Ford team—including global thermal teams, CAD departments, CAE integration teams, D&R, and other relevant attributes—ensuring alignment and integration of global strategies and standards. Maintain a commitment to delivering high-quality CAE results and solutions across all phases of the design process, while continuously improving processes and methodologies to enhance accuracy, CAE capabilities, and CAD-to-results turnaround time, all within cost-effective frameworks. Provide expert technical recommendations on design optimizations, resolution of engineering issues, and countermeasures, informed by in-depth analysis and interpretation of CAE data. Present and share insights and findings with thermal program engineers, department partners, and leadership, ensuring clear and effective communication of technical results and strategic decisions. Document all CAE work and outcomes in accordance with Ford's Thermal Process guidelines, ensuring full traceability and compliance with internal procedures for project tracking and reporting.

Requirements

Bachelor's degree in engineering
3+ years of professional experience in Product Engineering is required
3+ years of hands-on expertise in utilizing Computational Fluid Dynamics (CFD) and Computer-Aided Design (CAD) tools to conduct comprehensive thermal analysis for complete vehicle systems.
3+ years of experience using advanced simulation and modeling software tools such as Catia/3DX/TeamCenter, ANSA/Hypermesh, TAITherm, CCM+/UH3D/OpenFOAM, and EnSight, demonstrating an ability to leverage these tools to deliver detailed, high-fidelity thermal and fluid flow analyses, particularly in the context of automotive or aerospace applications.

Nice To Haves

Master of Science in Mechanical or Aeronautical Engineering, or a higher degree, with a specialization in fluid mechanics, heat transfer, or HEV battery technologies.
5+ years of hands-on expertise in utilizing Computational Fluid Dynamics (CFD) and Computer-Aided Design (CAD) tools to conduct comprehensive thermal analysis for complete vehicle systems.
Experience working within a globally distributed team environment.

Responsibilities

Lead and execute comprehensive vehicle transient thermal CAE (Computer-Aided Engineering) modeling from inception to completion, including CAD data acquisition, model cleanup, meshing, boundary condition setup, and post-processing analysis.
Conduct and support advanced front-end CAE analyses, such as 3D airflow simulations, heat exchanger and fan sizing, as well as optimizing heat exchanger configurations and front-end openings.
Collaborate on optimizing front-end openings and grille designs to achieve vehicle airflow and performance targets throughout various stages of vehicle development.
Perform CAE evaluations on exterior design proposals from the Studio, providing support for the design theme selection process, and ensuring alignment with overall performance objectives during the studio design phase.
Facilitate seamless collaboration with the Aerodynamics team, ensuring that thermal design considerations are balanced and optimized in conjunction with aerodynamic efficiency to meet overarching vehicle performance goals.
Work closely with the thermal program team and key stakeholders across the company, ensuring the delivery of optimal thermal environments for all under-hood and body components throughout the development lifecycle.
Evaluate and optimize the cabin thermal environment, contributing to the enhancement of cabin thermal energy efficiency and human comfort, while ensuring compliance with comfort standards and performance benchmarks.
Interface regularly with the global Ford team—including global thermal teams, CAD departments, CAE integration teams, D&R, and other relevant attributes—ensuring alignment and integration of global strategies and standards.
Maintain a commitment to delivering high-quality CAE results and solutions across all phases of the design process, while continuously improving processes and methodologies to enhance accuracy, CAE capabilities, and CAD-to-results turnaround time, all within cost-effective frameworks.
Provide expert technical recommendations on design optimizations, resolution of engineering issues, and countermeasures, informed by in-depth analysis and interpretation of CAE data.
Present and share insights and findings with thermal program engineers, department partners, and leadership, ensuring clear and effective communication of technical results and strategic decisions.
Document all CAE work and outcomes in accordance with Ford's Thermal Process guidelines, ensuring full traceability and compliance with internal procedures for project tracking and reporting.