Staff Thermal Systems Test Engineer

OverviewDesign and build thermal test assets spanning a range of size, scope and complexity: this could range from a simple coolant bench test to characterize a valve, to a partially completed refrigeration system with coolant and air loops, to a fully instrumented vehicle. Automate / script HIL testers that can replicate boundary conditions, loads etc. felt by a thermal system across a wide range of possible scenarios. Work with modeling engineers to validate predictions – propose tests based on prediction weaknesses, learn how to run the models themselves. Collaborate closely with controls engineers to validate the SW and propose improvements. Work closely with test and integration engineers to debug control algorithms at the bench and vehicle level. Lead engineering test fleets – these may consist of bucks and/or vehicles. Plan critical test campaigns – both at the wind tunnel and in the field. ResponsibilitiesDesign and build thermal test assets and automate testing to replicate real-world boundary conditions and scenarios.Lead engineering test fleets (buck/test vehicles) and plan critical test campaigns in wind tunnel and field environments.Collaborate with modeling, controls, test and integration engineers to validate predictions, SW, and control algorithms; propose improvements and debug at bench and vehicle levels. QualificationsB.S. in Mechanical Engineering or a related field. Foundational background in thermal systems (heat transfer, thermodynamics, fluid dynamics).4+ years of experience using modeling tools of various scales (GT, Python, MATLAB/Simulink, Dymola, TAITherm or similar).Experience with basic programming best practices (readable, reusable code).Experience working with high voltage powertrain and thermal systems; experience diagnosing and repairing HVAC components and systems.Safe management of glycol, AC refrigerant, and oil-based liquids and gases.Knowledge of thermal and fluid measurement sensor installation and calibration; experience with data acquisition systems and related sensors; ability to interpret and create wiring diagrams for test fixture construction.Graduate Degree in Mechanical Engineering with a focus on thermal engineering or energy systems (preferred).Real-world product development experience using tests to design, validate and continuously improve a thermal system used by customers daily.Deep experience with refrigeration systems (compressors, heat exchangers, valves, sensors, charge and oil management) applied to automotive products; deep experience with HVAC design (hardware, control strategies, energy flows within the cabin, glass properties).Experience modeling non-linear flow/energy circuits with first principles; familiarity with battery, motor/inverter and electronics thermal/electrical models.Familiarity using 3D CAD software collaboratively (NX, Catia, 3DX); proficiency using collaborative work tracking tools such as JIRA, Confluence and GitHub.Testing/laboratory experience with refrigeration loops, coolant and air circuits.A willingness to work cross-functionally in a dynamic environment as part of a high-performing team; a system approach to design and development with commitment to exceptional delivery and continuous improvement.Experience with controls methods for automotive thermal systems. BenefitsAs 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. OtherVisa sponsorship is available for this position. Verification of employment eligibility will be required at the time of hire. Ford #J-18808-Ljbffr

Created: 2025-09-25