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 utilityscale 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
Containerlevel airflow and liquid cooling performance
Hotspot formation and temperature gradients

Perform steadystate and transient thermal simulations under:

Normal operation
Highpower and longduration load profiles
Environmental extremes and fault scenarios

Design Support & Optimization

Support thermal and mechanical teams with simulationdriven 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 coldplate 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.

SystemLevel Analysis

Contribute to systemlevel thermal trade studies for:

Utilityscale 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 subjectmatter 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

Handson expertise with CFD tools such as:

Ansys Fluent / Icepak
StarCCM+
SIMcenter
Similar commercial CFD platforms

Experience modeling battery thermal behavior (lumped or detailed approaches).

System & Product Experience

Experience supporting stationary energy storage or similar largescale energy systems preferred.
Understanding of thermal challenges in highenergy, longduration battery systems.
Ability to interpret simulation results in the context of realworld operational constraints.

Preferred Qualifications

Bachelor's or Master's degree in Mechanical, Thermal, or Aerospace Engineering.
Experience with:

CFD automation or scripting
Multiphysics simulations (thermalelectrical 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 nonCFD stakeholders.
Ownership mentality and attention to detail.
Comfortable working in a fastpaced, productdriven environment.

Senior CFD Simulation Design Engineer BESS