CFD Engineer (CAE) – Propulsion and Battery Systems

Role

As a CFD Engineer – Propulsion and Battery Systems, you will lead DFMEA-driven 3D

Computational Fluid Dynamics (CFD) analysis at the component, subsystem, and

system level to optimize thermal performance and system reliability across GM propulsion

systems. Operating within a DFMEA-centric environment, you will use virtual engineering

to identify failure modes, evaluate severity/occurrence risks, and drive robust risk

mitigation strategies for propulsion systems, specifically battery and power electronics

thermal performance, durability and safety requirements.

Work Arrangement

Hybrid work position: This position does not require an employee to be on-site full-time to

perform most effectively. The employee’s role enables them to work at a GM facility or off-

site as frequently as needed or desired.

Primary Responsibilities

● Perform DFMEA-aligned 3D CFD analysis focusing on high-voltage battery systems

and power electronics to identify and mitigate critical thermal failure modes at the

cell, module, pack, and system level.

● Simulate and quantify battery Thermal Runaway Propagation (TRP), venting gas

dynamics, and safety physics under severe abuse scenarios to validate DFMEA

mitigation designs, barrier integrity, and failure containment controls.

● Lead thermal risk assessments during early architecture definition and concept

selection using rapid CFD trade studies to eliminate high-risk failure modes prior to

design freeze.

● Correlate virtual failure mode predictions with physical test and validation data to

ensure simulation fidelity in predicting real-world failure thresholds and reliability

margins.

● Clearly and effectively communicate analysis plans, assumptions, and results to

internal and external stakeholders using presentations, reports, and design reviews.

● Meet or exceed timing, quality, and cost targets within structured product

development processes.

● Participate in and/or lead benchmarking and advanced methods activities to

continuously improve GM’s virtual engineering capabilities in CFD and multi-

physics analysis.

Required Skills and Experience

● 5+ years of experience with simulation, design, testing, or release of propulsion-

related systems (e.g., engines, transmissions, e-drive units, batteries, power

electronics, thermal management systems).

● Hands-on experience with at least one commercial 3D CFD software package

(e.g., STAR-CCM+, Simerics-MP+, Fluent, or equivalent).

● Demonstrated understanding of heat transfer and fluid mechanics (conduction,

convection, radiation, pressure loss, turbulence, etc.) applied to real engineering

systems.

● Familiarity or practical experience with vehicle propulsion system design,

operation, or testing.

● BS in Mechanical or Aerospace Engineering (or closely related field) required.

Preferred Skills and Experience

● 5+ years of advanced experience with 3D CFD thermal and fluid analysis

specialized for battery pack and module systems.

● Experience in modeling battery Thermal Runaway Propagation (TRP) and gas

venting dynamics under severe thermal abuse and cell failure conditions.

● Experience with electro-thermal multi-physics coupling, integrating

electrochemical heat generation models with 3D CFD for cell characterization,

module, and pack simulations.

● Expertise in Artificial Intelligence (AI), Machine Learning (ML), and Reduced

Order Modeling (ROM) for rapid thermal prediction, digital twins, and real-time

CFD surrogate modeling

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