CFD Engineer

Job Title: Senior Simulation & Analysis Engineer (CFD Analyst)

Job Description

This Senior Simulation & Analysis Engineer role focuses on advanced CFD analysis for diesel, natural gas, and battery electric trucks within a state-of-the-art research and development organization. You will analyze complex thermo-mechanical systems, ensure cooling performance and thermal management requirements are met, and provide clear, data-driven design recommendations. Working closely with cross-functional engineering teams, you will run component, subsystem, and complete vehicle simulations, validate results against test data, and lead technical discussions that shape future heavy-duty truck products for the North American market. As a technical leader, you will coordinate design changes, drive simulation strategy improvements, and own the analysis process from initial concept through to stakeholder approval.

Responsibilities

• Conduct CFD analysis of components and sub-systems, including heat exchangers, exhaust systems, air intake systems, and related under-hood components.
• Run complete vehicle thermal and airflow simulations to evaluate cooling performance and overall thermal management for heavy-duty trucks.
• Perform technical research, post-process and interpret CFD results, and translate findings into clear engineering reports and actionable design recommendations.
• Identify and help rectify potential design issues early in the development process, and propose improvements to existing designs based on simulation outcomes.
• Collaborate with engineering, testing, and project teams to plan, develop, and coordinate test plans that support simulation activities.
• Define and provide instrumentation roadmaps for physical testing, and interpret test data to refine models and guide design decisions.
• Synthesize information from simulations, test results, technical requirements, and historical data to identify opportunities for functional improvements across vehicle systems.
• Formulate and communicate actionable technical recommendations to stakeholders across the engineering organization.
• Lead cross-functional engineering and CAE teams to address potential design flaws and drive solutions from concept through to final production release.
• Perform validation studies by comparing CFD predictions to experimental measurements, and refine simulation methodologies to improve accuracy and robustness.
• Coordinate with global CFD and technical strategy teams to develop and enhance simulation strategies, workflows, and best practices.
• Own the analysis process for assigned projects, ensuring that results, recommendations, and design outcomes meet the expectations of all stakeholders.
• Support the development and maintenance of high-quality CFD models, including geometry preparation, meshing, and setup for complex analysis types.
• Apply design of experiments and other structured validation techniques to plan and interpret experimental measurements.
• Contribute to continuous improvement of simulation processes, including automation, standardization, and documentation of methods.

Essential Skills

• Bachelor's degree in Mechanical Engineering or Aerospace Engineering.
• At least 5 years of hands-on experience in Computational Fluid Dynamics (CFD).
• Strong experience in fluid dynamics, heat transfer, and thermodynamics.
• Proven track record of validating and optimizing vehicle designs using CAE simulation tools.
• Experience performing CFD for automotive cooling, airflow, thermal management, and aerodynamics.
• Proficiency in building fully detailed CFD models for complex analysis types, including geometry cleanup using commercial CAE pre-processing tools such as HyperMesh or similar.
• Approximately 5 years of experience using commercial CFD software such as PowerFLOW, StarCCM, Fluent, and TaiTherm.
• Experience with 1D simulation tools for flow calculations, including the ability to run coupled simulations with system-level models.
• Proficiency with Matlab and Simulink for modeling, analysis, and integration with simulation workflows.
• High level of experience working in Linux operating systems, including use of high-performance computing (HPC) systems to submit, monitor, and manage CAE jobs.
• Practical, hands-on experience with validation and experimental measurements, including planning and executing design of experiments.
• Ability to translate complex simulation and test data into clear, concise engineering reports and presentations.
• Strong collaboration skills to work effectively with cross-functional engineering, testing, and product design teams.
• Ability to lead technical discussions, influence design decisions, and drive issues to resolution.

Additional Skills & Qualifications

• Experience in automotive cooling airflow, thermal management, and aerodynamics is considered a strong advantage.
• Experience with additional commercial CAE pre-processing tools beyond HyperMesh is beneficial.
• Familiarity with 1D simulation tools such as Amesim or similar system-level modeling software is a plus.
• Experience running coupled simulations that integrate 3D CFD with 1D system models is desirable.
• Experience with shell or Linux scripting to automate repetitive simulation and post-processing tasks is a plus.
• Experience coordinating with global or geographically distributed technical teams is advantageous.
• Demonstrated ability to improve and standardize simulation methodologies and best practices.
• Strong analytical thinking, problem-solving skills, and attention to detail in both modeling and experimental work.
• Effective written and verbal communication skills, with the ability to convey complex technical information to both technical and non-technical stakeholders.

Work Environment

This role operates within a modern research and development environment focused on high-tech transportation solutions for the North American market. You will work closely with cross-functional teams including chassis, cab, electrical, testing, and product design groups, collaborating on future heavy-duty truck platforms powered by diesel, natural gas, and battery electric technologies. The position is highly technical and simulation-driven, with extensive use of commercial CFD tools such as PowerFLOW, StarCCM, Fluent, and TaiTherm, as well as CAE pre-processing tools like HyperMesh. Daily work involves operating in a Linux-based environment and leveraging high-performance computing (HPC) systems to submit, monitor, and manage large-scale CAE jobs. You will interact regularly with physical testing teams, laboratories, and test facilities to plan validation activities, define instrumentation, and interpret experimental data. The culture emphasizes innovation, data-driven decision making, and close collaboration across engineering disciplines, providing opportunities to influence product design from concept through production.

This is a Contract position based out of Greensboro, NC.

The pay range for this position is $40.00 - $45.00/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 Greensboro,NC.

This position is anticipated to close on Jun 12, 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 30,000 consultants and more than 4,500 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500.

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 actalentaccommodation@actalentservices.com 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.

Salary : $40 - $45