Thermal Systems CAE Engineer

Thermal Systems CAE Engineer 

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In this 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. This role requires an in-depth understanding of vehicle systems and operations, ensuring seamless collaboration with thermal program engineers and senior leadership teams. The engineer will lead and execute full-vehicle transient thermal CAE modeling, overseeing every phase of the process—from initial data collection and CAD clean-up, to meshing, boundary condition setup, and post-processing. The focus is on assessing the thermal performance of front-end cooling systems, the thermal robustness of all under-hood and body components, and cabin human comfort.

The CAE Engineer will be required to leverage both analytical and creative problem-solving to generate technical insights and formulate actionable recommendations for issue resolution, countermeasures, and design optimizations based on CAE simulations and test data. A crucial aspect of the role involves interacting with Ford’s global teams—including the global thermal team, CAD specialists, CAE integration experts, design and release engineers, and other related departments—to ensure alignment and consistency across all stages of development. The engineer will be responsible for presenting their work to thermal program engineers, department partners, and leadership, articulating key findings and design decisions effectively.  Additionally, the CAE Engineer will document all CAE-related activities and outcomes according to Ford’s Thermal process, ensuring comprehensive task traceability and compliance with internal protocols.

The role requires a forward-thinking mindset, with a focus on continuously innovating and improving CAE processes, particularly in areas such as accuracy, simulation capabilities, CAD-to-results turnaround time, and cost-effectiveness. This will be achieved through the identification and implementation of process improvements aimed at enhancing overall efficiency and performance.

What you'll do...

• 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.

You'll have...

• 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.

Even better, you may have...

• 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.

You may not check every box, or your experience may look a little different from what we've outlined, but if you think you can bring value to Ford Motor Company, we encourage you to apply!

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a changemaker, a technical expert, a culture builder…or all of the above? No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service 
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day 
• Paid time off and the option to purchase additional vacation time. 

This position is a salary grade 7 and ranges from $84,480-141,360., This position is a salary grade 8 and ranges from $96,720-162,120.

For more information on salary and benefits, click here: https://fordcareers.co/GSR

Visa sponsorship is not available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.

We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status or protected veteran status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1-888-336-0660.

This position is hybrid. Candidates who are in commuting distance to a Ford hub location may be required to be onsite four or more days per week. #LI-Hybrid #LI-MK1