Battery Thermal Engineer

Airsys Cooling Technologi • Anderson, South Carolina • 13m ago

Job Summary:

As a Battery Thermal Engineer, you will play a key role in the development and optimization of advanced thermal management systems for battery packs used in electric vehicles (EVs), energy storage systems (ESS), and other high-performance applications. This role requires strong expertise in heat transfer, fluid dynamics, and thermal system design, with a focus on ensuring battery safety, performance, and longevity under varying operating conditions. You will collaborate with cross-functional teams across mechanical design, materials science, and system integration to develop innovative liquid cooling and hybrid thermal solutions that optimize temperature uniformity and system efficiency.

Responsibilities:

Design and analyze thermal management systems for battery packs, including liquid cooling plates, immersion cooling solutions, and air cooling systems.
Develop thermal models (1D, 3D) to simulate heat generation, transfer, and dissipation within battery cells, modules, and packs.
Conduct thermal performance testing and validation on prototypes, correlating simulation results with real-world data.
Work closely with mechanical, electrical, and software engineers to ensure seamless integration of thermal management systems into overall battery design.
Optimize coolant flow paths, heat exchanger configurations, and thermal interface materials (TIMs) to improve cooling efficiency and reduce thermal gradients.
Evaluate new materials and advanced cooling technologies, including two-phase cooling, direct liquid immersion, and phase change materials (PCM) for next-generation thermal systems.
Develop and maintain design guidelines and best practices for battery thermal management.
Support root cause analysis and resolution of thermal issues arising during testing, manufacturing, and field operation.
Interface with suppliers and external partners to evaluate thermal components and ensure they meet performance and cost requirements.
Other tasks assigned

Basic Qualifications:

Bachelor’s degree in mechanical engineering, Thermal Engineering, or a related field.
Solid understanding of heat transfer, thermodynamics, and fluid dynamics.
Hands-on experience in thermal testing, instrumentation, and data analysis.
Strong analytical and problem-solving skills with the ability to work from first principle

Preferred Qualification:

Master’s degree or PhD in Mechanical Engineering, Thermal Engineering, or related discipline.
Experience in battery thermal management for EVs, ESS, or aerospace applications.
Familiarity with liquid cooling system design, including pumps, heat exchangers, and manifolds.
Experience with thermal modeling and simulation tools (e.g., ANSYS Fluent, STAR-CCM+, COMSOL, or similar).
Experience with Design for Additive Manufacturing (DfAM) for liquid-cooled components.
Knowledge of battery safety requirements and thermal runaway mitigation techniques.
Experience working with cross-functional teams on complex system integration projects.
Excellent verbal and written communication skills, including the ability to present technical information to both internal and external stakeholders.
Passion for energy storage technologies and sustainable innovations.
High level of attention to detail and accuracy in all work.
Passion in startup for long term achievement is desired.