Thermal Design & simulation Engineer at The Eplane Company in Tamil Nadu, Chennai, India

Job Description - Thermal Design & simulation Engineer

Job Summary

We are hiring a Thermal Engineer to lead the design, simulation, and validation of thermal systems for our next-gen eVTOL propulsion platforms. You’ll work on radiators, forced convection cooling, motor and inverter thermal analysis, and powertrain packaging, using tools like STAR-CCM or Ansys . With high power and torque densities, thermal management is critical to our system’s performance.

Key Responsibilities

Lead the design and analysis of thermal management systems for electric powertrains (motors, inverters, gearboxes) in eVTOL applications.
Model and optimize radiator geometry, airflow ducting, and integration with propeller-induced or free-stream flows.
Drive thermal design of electric motors and inverters, including winding cooling, stator housing, Fin plate and jacket cooling.
Develop and validate complete cooling system architectures including pump sizing, plumbing layout, and pressure drops.
Collaborate cross-functionally with mechanical, electrical, and controls teams for thermal packaging, placement, and interface design.
Define test plans, support thermal testing, and perform simulation-to-test correlation for performance validation.
Generate technical documentation, DVP&R, and design reports for internal and external stakeholders.
Perform CFD simulations (forced convection, natural convection, conjugate heat transfer, radiator sizing) using STAR-CCM+

Required Qualifications

Bachelor’s or Master’s degree in Mechanical, Aerospace, Thermal Engineering or related field.
5+ years of industry experience in thermal system design and analysis, ideally in aerospace, automotive, or high-performance EVs.
Proficient in thermal-fluid design & simulations (CFD, CHT, radiator design) and analysis.
Solid understanding of forced convection cooling, especially with non-uniform/ducted airstreams such as from propellers or ambient airflow.
Proven experience in electric motor and inverter thermal design.
Strong understanding of thermal packaging, heat exchanger performance, and power electronics cooling.
Ability to work from concept to validation, including simulation, hardware definition, and testing.
Familiarity with interpreting CFD results and translating into design decisions and improvements.

Nice to Have / Preferred Skills

Experience with aerospace applications, especially eVTOL, UAVs, or high-speed electric aircraft.
Knowledge of coolant plumbing layout, hose/connector selection, and pressure-drop analysis.
Exposure to motor cooling systems, phase change materials.
Familiarity with Siemens Simcenter, AMESim, or other 1D thermal simulation tools.
Experience in test bench setup, data acquisition, and thermal sensor instrumentation.
Hands-on experience in CAD tools (CATIA, SolidWorks, etc) for mechanical design related to thermal systems.
Experience working in cross-disciplinary teams including mechanical, controls, and integration engineering.

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Thermal Design & simulation Engineer

Job Description - Thermal Design & simulation Engineer

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