Job Title: Thermal Simulation Engineer
Job Description
This role focuses on developing and applying advanced thermal and structural simulation models to optimize complex electromechanical product designs, with a particular emphasis on current-carrying components such as connectors, busbars, and cable assemblies. The engineer will work closely with design, manufacturing, and testing teams to validate simulations, resolve intricate design and manufacturing issues, and drive product performance improvements through data-driven insights and robust analysis.
Responsibilities
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Develop and implement advanced thermal and structural simulation models to optimize product designs, manufacturing processes, and system performance, especially for current-carrying products such as connectors, busbars, and cable assemblies.
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Perform detailed calculations and simulations on temperature distribution across systems to evaluate heat transfer, thermal behavior, and system reliability.
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Conduct thermo-mechanical and structural simulations to support design optimization, material selection, and validation from concept through to production.
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Simplify complex CAD geometries to create efficient and accurate structural and thermal simulation models.
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Apply in-depth knowledge of mechanical design, conductive and convective heat transfer, and fluid flow mechanics to solve complex engineering problems.
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Collaborate with design, manufacturing, and testing teams to correlate finite element analysis (FEA) results with physical test data and refine models accordingly.
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Use Design of Experiments (DOE) and optimization techniques to systematically improve designs and processes based on simulation outcomes.
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Lead and direct cross-functional teams in addressing and resolving intricate design and manufacturing challenges identified through simulations.
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Analyze complex simulation results to identify performance gaps, recommend design or process changes, and drive continuous improvement.
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Maintain, update, and enhance simulation models to ensure ongoing accuracy, relevance, and alignment with evolving product designs and technologies.
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Validate concept designs using simulation techniques, evaluate design robustness, and confirm compliance with critical-to-function requirements.
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Deploy FEA techniques using both implicit and explicit approaches with software tools such as Ansys Workbench, LS-DYNA, HyperMesh, Simufact, Moldex3D, OptiSLang, Icepak, Maxwell, and Ansys HFSS.
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Translate real-world engineering problems into appropriate FEA models, interpret analysis results, and select optimal solutions, including linear and non-linear analyses under multiple physics domains.
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Monitor and evaluate simulation software capabilities, industry trends, and emerging tools to enhance analysis methodologies and productivity.
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Collaborate closely with design and validation teams to support design optimization, improve product robustness, and shorten development cycles.
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Understand and consider the financial impact of engineering activities and design decisions on projects and products.
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Apply LEAN, Six Sigma, or Kaizen techniques to live projects to improve efficiency, quality, and consistency in simulation and design workflows.
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Support knowledge sharing through technical documentation, and contribute to technical paper publications and patent applications where applicable.
Essential Skills-
Bachelor’s degree (BE/B.Tech) in Mechanical or Electrical Engineering.
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3–5 years of industry experience in simulation, thermal analysis, or related engineering fields.
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Strong expertise in Ansys Workbench for structural and thermal finite element analysis.
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Hands-on experience developing and implementing complex thermal simulation models for current-carrying products such as connectors, busbars, and cable assemblies.
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Proficiency in conducting thermo-mechanical and structural simulations for design optimization, material selection, and validation.
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Ability to simplify complex CAD geometries for efficient structural and thermal simulations.
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In-depth knowledge of mechanical design principles, conductive and convective heat transfer, and fluid flow mechanics.
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Experience with FEA techniques using implicit and explicit approaches for linear and non-linear analyses.
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Proficiency with FEA tools such as ANSYS Workbench, LS-DYNA, HyperMesh, Simufact, Moldex3D, OptiSLang, Icepak, Maxwell, and Ansys HFSS.
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Experience with system simulation tools such as MATLAB and Simulink.
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Proficiency with CAD tools such as PTC Creo and SpaceClaim.
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Programming skills in Python, Microsoft VBScript, and Power IB.
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Strong skills in using Microsoft Office tools for reporting, data analysis, and documentation.
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Knowledge of associated manufacturing processes including molding, stamping, plating, crimping, and assembly.
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Understanding of soldering, crimping, and welding technologies as they relate to product design and simulation.
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Experience correlating test data with simulation results to refine models and improve accuracy.
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Expertise in CAE tools, optimization techniques, and engineering testing methods.
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Experience working with connector products made from plastic and sheet metal.
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Knowledge of material science, including metals, resins, and hyperelastic materials, and their implementation in simulation models.
Additional Skills & Qualifications-
Master’s degree (M.Tech) in Mechanical or Electrical Engineering is preferred.
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Knowledge of product design processes and methodologies across the product lifecycle.
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Familiarity with technical paper publication processes and experience contributing to or authoring technical papers.
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Experience in applying for patents related to simulation, design, or product innovations.
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Demonstrated ability to lead cross-functional teams and drive resolution of complex design and manufacturing issues.
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Experience with Design of Experiments (DOE) and advanced optimization techniques to enhance design robustness and performance.
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Practical experience implementing LEAN, Six Sigma, or Kaizen methodologies on engineering projects.
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Strong analytical and problem-solving skills with the ability to interpret complex simulation data and communicate insights clearly.
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Awareness of financial considerations and cost implications of engineering decisions and design changes.
Work Environment
The role operates in a technology-driven engineering environment that emphasizes advanced simulation, design optimization, and close collaboration with cross-functional teams. You will work extensively with state-of-the-art FEA and CAE tools, including ANSYS Workbench, LS-DYNA, HyperMesh, Simufact, Moldex3D, OptiSLang, Icepak, Maxwell, Ansys HFSS, as well as system simulation platforms like MATLAB and Simulink and CAD tools such as PTC Creo and SpaceClaim. The position involves regular interaction with design, manufacturing, testing, and validation teams, supporting projects from early concept through production. The environment encourages continuous improvement through LEAN, Six Sigma, and Kaizen practices, along with ongoing learning in material science, manufacturing technologies, and simulation methodologies. Work is primarily office-based or lab-based using standard engineering workstations and software, with a focus on precision, documentation, and collaborative problem-solving.
Job Type & Location
This is a Contract position based out of Middletown, PA.
Pay and Benefits
The pay range for this position is $71.00 - $71.00/hr.
Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following:
- Medical, dental & vision
- Critical Illness, Accident, and Hospital
- 401(k) Retirement Plan – Pre-tax and Roth post-tax contributions available
- Life Insurance (Voluntary Life & AD&D for the employee and dependents)
- Short and long-term disability
- Health Spending Account (HSA)
- Transportation benefits
- Employee Assistance Program
- Time Off/Leave (PTO, Vacation or Sick Leave)
This is a fully onsite position in Middletown,PA.
Application Deadline
This position is anticipated to close on Jul 14, 2026.
About Actalent
Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.
The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.
If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email [email protected] for other accommodation options.
San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.
Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.
Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.
