Senior Thermal Hardware Engineer – ECU

Job Description

The Role:

General Motors is at the forefront of the transformation of automotive with the electrification of our portfolio and the development of leading-edge central compute and autonomous capabilities. Our ECU Mechanical & Thermal Design team is a dynamic high-energy and innovative group focused on developing mechanical and thermal design of next generation ECUs (Electronic Control Units). The team is responsible for developing Mechanical and Thermal design of new next gen ECU designs with math CAD and analysis. The team also reviews and approves production ECU design changes.

We are seeking a high-performing Thermal Design Engineer interested in leading the in-house development of electronics design. You will be responsible for the thermal design development and review of Electrical Controllers and cooling solutions for our next generation SDV (Software Defined Vehicle) architecture. You will be dependent upon building strong partnerships with internal and external customers.

What Youll do:

• Translate CTRS / vehicle requirements into thermal requirements and design constraints (ambient temp underhood vs incabin environment duty cycles altitude etc.)
• Define thermal budgets (Tj/Tc limits margins) for SoCs power devices memories and other critical components.

• Perform steadystate and transient simulations to optimally size heatsinks cold plates fins airflow paths and liquid loop elements.
• Evaluate options such as passive cooling forced air liquid cooling heat pipes and vapor chambers and recommend the best architecture.

• Work with cross-functional teams to implement your thermal design strategy.
• Develop thermal test plans and run thermal characterization tests.

• Provide thermal inputs to DFMEA DRBFM and design reviews; clearly quantify risks margins and mitigations
• Present thermal status trade studies and recommendations at PDTs design reviews and leadership updates

Your Skills & Abilities (Required Qualifications)

• BS in Mechanical Engineering (or related discipline) with strong focus on heat transfer and thermodynamics.
• 5 years of experience in thermal design and analysis of electronics (ECUs servers power electronics or similar).
• Handson experience with thermal simulation tools (e.g. Ansys Icepak FloEFD Flotherm or equivalent) and data analysis (e.g. MATLAB Python or similar).
• Strong understanding of:
  • Conduction convection (forced and natural) radiation
  • Thermal interface materials (TIMs gap pads PCMs)
  • Heatsink and coldplate design flow/pressure tradeoffs
• Practical experience defining or executing thermal test plans in environmental chambers and correlating models to lab results.
• Ability to interpret electrical power maps/BOMs derive thermal loads and work closely with EE/PCB teams.
• Strong communication skills; able to present complex thermal trade studies clearly to both technical and nontechnical stakeholders.
• Demonstrated ability to work across crossfunctional and global teams and manage multiple programs in parallel.

What Will Give You a Competitive Edge (Preferred)

• MS or PhD in Mechanical Engineering (Thermal/Fluids) or related field.
• Automotive experience with automotive environmental/thermal standards.
• Experience with highpower SoCs GPUs power modules or invehicle central compute ECUs.
• Familiarity with mechanical design of housings and ECU packaging (castings injection molded parts sealing IP ratings).
• Experience integrating thermal design into DFMEA/DRBFM/DFx processes.
• Prior work with ECU Designs

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