Thermal Simulation Engineer-EV

1 week ago

Pune Maharashtra India, Maharashtra Kalbhorz Full time
Hiring: Thermal Simulation Engineer – Electric Motors & Drives

Location: Pune/Pimpri-Chinchwad, India (On-site)

Experience: 3–7 Years

Industry: Electric Vehicles, Powertrains, Mobility Tech


About Us

At Kalbhorz , we’re building next-generation axial flux electric motors and integrated motor-drive systems for high-performance mobility—ranging from electric two-wheelers and drones to EVs and marine applications. As we scale, we’re seeking a driven Thermal Simulation Engineer to optimize our motor and drive platforms for high efficiency, reliability, and compactness.


️ Job Description

As a Thermal Simulation Engineer, you will be responsible for developing and validating detailed thermal models for electric motors, inverters, and motor controllers. You’ll collaborate closely with design, hardware, and testing teams to simulate heat dissipation, cooling strategies, and thermal stress across real-world drive cycles.


Key Responsibilities
  • Develop thermal models of electric motors (axial flux, BLDC, SRM) and inverters using Ansys, COMSOL, or equivalent tools.
  • Simulate heat flow, cooling (liquid/air/natural convection), and temperature rise in motor windings, cores, and power electronics.
  • Optimize thermal management strategies, including material selection and passive/active cooling methods.
  • Work with the mechanical team to integrate simulation results into enclosure/casing design.
  • Correlate thermal simulations with physical test results and iterate for accuracy.
  • Generate detailed thermal performance reports, design guidelines, and risk mitigation strategies.
  • Collaborate with cross-functional teams (electromagnetic, mechanical, PCB, controls) to co-develop robust systems.


Job Requirements
  • Bachelor’s or Master’s in Mechanical, Electrical, Thermal Engineering, or related fields.
  • 3–7 years of experience in thermal simulation and analysis, preferably in the EV, eMobility, or powertrain sector.
  • Proficiency in thermal FEA/CFD tools like Ansys Icepak, Fluent, COMSOL, FloTHERM, or Star CCM+.
  • Strong understanding of electric motor design, losses (copper, core, switching), and cooling systems.
  • Knowledge of power electronics packaging and thermal behavior of MOSFETs, IGBTs, SiC modules is a strong plus.
  • Ability to interpret drive cycles, duty loads, and usage scenarios into real-time simulation cases.
  • Hands-on experience with thermal testing and sensor integration is preferred.
  • Strong communication, documentation, and cross-team collaboration skills.


Nice to Have
  • Experience with Electric Motor
  • Exposure to automotive standards for thermal reliability and validation
  • Familiarity with system-level simulation tools (e.g., Simulink, Matlab, GT-Suite)
  • Previous work with liquid cooling loop design for compact electric drivetrains


What We Offer
  • Work on cutting-edge thermal challenges in next-gen EV powertrains
  • A high-impact role in a rapidly growing startup
  • Access to state-of-the-art labs, tools, and simulation resources
  • Competitive salary + ESOP + performance-linked bonus
  • Flat hierarchy, innovation-driven culture


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