Senior Battery Thermal Analyst

In this role, you will:

• Perform detailed thermal analysis and simulations to evaluate battery cell, module, and pack-level thermal behavior under various operating conditions.
• Develop thermal models using CFD, FEA, and multi-physics simulation tools to optimize battery cooling and heating strategies.
• Design and execute thermal validation tests, including calorimetry, thermal imaging, and environmental chamber testing, to correlate simulations with real-world performance.
• Collaborate with battery design, powertrain, and system integration teams to define and validate thermal management solutions.
• Conduct thermal runaway modeling, propagation analysis, and safety assessments to enhance battery system reliability.
• Support certification efforts, ensuring compliance with aviation safety standards and thermal performance requirements.

What you will do:

• As part of the ESPS organization and deployed in the Battery Thermal Engineering sub-team, you will act as a Senior Battery Thermal Analyst for a novel type of aircraft development targeting the autonomous Urban Air Mobility (UAM) market.
• You will take part in developing high-fidelity thermal models and simulations to evaluate battery pack performance in real-world conditions.
• You will support cross-functional teams, including thermal engineers, battery design, and safety teams, to optimize thermal management strategies.
• You will help support problem-solving activities related to battery thermal challenges, including excessive heat generation, cooling system inefficiencies, and thermal runaway risks.
• You will take part in analyzing test data, correlating simulations with experimental results, and refining thermal models for accuracy.
• You will be responsible for designing thermal test plans, instrumentation setup, and data collection methodologies for validation testing.
• In some areas, you will be working closely with certification and regulatory teams to ensure compliance with aviation battery safety standards.
• You will plan and execute thermal simulations, sensitivity analyses, and failure mode assessments to support battery system safety and performance.
• As a Senior Battery Thermal Analyst, you will help define thermal design criteria, simulation methodologies, and validation processes for next-generation battery systems.

Requirements:

• B.S., M.S., or Ph.D. in Mechanical Engineering, Aerospace Engineering, Thermal Sciences, or a related field with at least 5+ years of experience in battery thermal analysis, preferably in aerospace, automotive, or energy industries.
• You have worked in battery systems, electric powertrains, or aerospace electrification industries.
• You have hands-on experience with thermal modeling and simulation tools such as ANSYS Fluent, COMSOL, STAR-CCM+, MATLAB, or GT-SUITE.
• You have a deep and applied knowledge of heat transfer, fluid dynamics, electro-thermal coupling, and multi-physics simulations.
• You have led projects that achieved thermal performance optimization, safety improvements, or efficiency enhancements in battery systems.
• You have experience in thermal test design, including sensor selection, test setup, and data analysis for correlation with simulations.
• You are familiar with aviation battery safety standards (DO-311A, ARP4761, AS6413) and industry best practices for thermal management.
• Experience with thermal runaway propagation modeling, fire suppression methods, and thermal testing techniques is a plus.
• This role may require up to 20% travel for testing, supplier visits, or regulatory engagements.