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.
