CFD/FEA Senior Engineer - Electronics Thermal Management

Job Requirements

About the Role

We're hiring a simulation engineer for thermal and structural analysis for compact, high-density consumer electronics such as smart wearables. You'll run CFD and FEA simulations to predict and solve thermal, thermo-mechanical and reliability problems.

Work Experience

Key Responsibilities-

- Build and run conjugate heat transfer (CHT) simulations at system, board and component level, including natural convection, forced convection and radiation.
- Model the thermal behavior of SoCs, PMICs, batteries, displays, cameras and other heat-dissipating parts in tight enclosures.
- Run transient analyses of power profiles and use cases and support thermal throttling and power budget strategy.
- Evaluate cooling solutions: heat spreaders, graphite sheets, vapor chambers, TIMs, phase-change materials and airflow paths.
- Run thermo-mechanical stress and warpage analysis on PCBs, solder joints, packages and enclosures.
- Predict solder joint fatigue and reliability under thermal cycling.
- Couple CFD temperature fields into FEA for Multiphysics evaluation.
- Turn simulation results into clear design recommendations for cross-functional teams.
- Correlate models with lab data (thermocouples, IR thermography, thermal chambers) and improve model accuracy.
- Help define thermal test plans and DVT/PVT validation.
- Run design-of-experiments (DOE), sensitivity studies and optimization.
- Build simulation best practices, templates and automation scripts.

Required Qualifications

- B.E./B.Tech or M.Tech/M.S. in Mechanical, Thermal, Aerospace or a related engineering field.
- Hands-on experience in thermal management using CFD or FEA.
- Proficiency with at least one CFD tool: Ansys Icepak, Fluent, Simcenter FloTHERM, Comsol Multiphysics, CFD++, or similar.
- Proficiency with at least one FEA tool: Ansys Mechanical, Abaqus, or similar.
- Solid grounding in heat transfer, fluid mechanics, solid mechanics and material behavior.
- Experience importing and simplifying CAD (Creo, SolidWorks, NX, DesignModeler, Space claim).
- Strong communication and reporting skills.

Preferred Qualifications

- Experience with wearables, mobile devices, AR/VR or other compact consumer electronics.
- Knowledge of battery thermal behavior and safety.
- Scripting for automation and post-processing (Python, MATLAB, APDL).
- Experience with multiphysics coupling (electro-thermal, thermo-mechanical).
- Familiarity with JEDEC thermal standards and package characterization (θJA, θJC, compact thermal models).
- Experience with thermal test equipment and model correlation.
- Exposure to optimization tools (optiSLang, HEEDS, modeFRONTIER).

Key Competencies

- Strong analytical problem-solving and engineering judgment.
- Able to balance simulation accuracy against program timelines.
- Works well with cross-functional, global teams.
- Takes ownership, with attention to detail.