Staff Engineer - Simulation & Validation
Rehlko is a global leader in energy resilience with over 100 years of history, delivering engines, generators, power conversion, UPS systems, EV components, microgrid controls, and clean energy solutions. Our purpose is creating an energy-resilient world for a better future, guided by values of Curiosity, Trust, Pace, and Excellence.
About the role
The Staff Engineer, Simulation & Validation leads thermal and fluid flow simulation activities and validates analytical results through experimental testing. This role supports development and optimization of engine thermal management systems, power electronics cooling solutions, fuel delivery systems, and exhaust systems. The position directly influences engine cooling system performance, generator thermal management solutions, power electronics cooling strategies, fuel and exhaust system optimization, product validation methodologies, and future simulation capabilities and engineering best practices.
Responsibilities
- Lead thermal and fluid flow simulations to evaluate and optimize cooling system performance using CFD tools, including Siemens STAR-CCM+ and comparable technologies.
- Analyze and optimize engine thermal management systems, including radiators, fans, airflow distribution, cooling packages, and related components.
- Perform simulation and validation activities for fuel delivery, exhaust, and thermal management systems to ensure design and performance targets are achieved.
- Design, evaluate, and optimize heat transfer solutions for power electronics and related applications.
- Develop analytical methods, processes, and optimization tools that improve thermal system performance, robustness, and cost effectiveness.
- Conduct experimental testing and data analysis to correlate simulation models with physical validation results.
- Partner with product development engineers, laboratory teams, suppliers, and cross-functional stakeholders to solve complex engineering challenges.
- Develop and publish technical reports, engineering standards, validation procedures, best-practice guidelines, and technical documentation.
- Research and evaluate emerging simulation technologies and tools, recommending new capabilities that enhance engineering effectiveness and product performance.
Requirements
- Bachelor’s degree in mechanical engineering or a related engineering discipline.
- Minimum of six (6) years of engineering experience in thermal systems, fluid dynamics, simulation, validation, or related technical disciplines (graduate-level research may be considered toward experience requirements).
- Demonstrated experience applying Computational Fluid Dynamics (CFD) tools to solve complex engineering problems.
- Strong understanding of heat transfer, thermodynamics, fluid flow, thermal management, cooling systems, and related engineering principles.
- Experience developing simulation models and validating analytical predictions through testing and experimentation.
- Effective technical communication skills, including the ability to present findings and recommendations to technical and non-technical audiences.
Qualifications
- Master's degree or PhD in Mechanical Engineering, Thermal Sciences, Fluid Dynamics, Heat Transfer, or a related field.
- Experience with Siemens STAR-CCM+ or similar CFD software.
- Experience supporting engine cooling systems, power generation equipment, power electronics cooling, heat exchangers, or thermal management systems.
- Experience correlating simulation models with laboratory and field validation data.
- Experience authoring technical papers, engineering standards, best practices, or white papers.
Benefits
- Competitive compensation and benefits
- Work-life flexibility
- Recognition and rewards
- Development and career opportunities
- A safe and inclusive workplace
- Health, vision, and dental insurance
- 401(k) with company matching
Pay
Salary range: $98,900.00–$125,600.00. The specific salary rate offered may be influenced by factors including the candidate’s experience, education, and work location.
Schedule
Hybrid (2–3 days per week on-site). Work location: N7650 County Rd LS, Sheboygan, WI 53083. Applicants must be authorized to work in the US without requiring new or transfer visa sponsorship now or in the future.