Lead Engineer FEA/CFD Simulation

Your contribution:

We seek a Mechanical/Thermal/Chemical Engineer with expertise in FEA/CFD and AI to develop advanced simulation models for battery systems. This role focuses on supporting Reduced Order Models (ROM), digital twin technology, and the use of optiSLang for optimizing thermal and mechanical designs. The successful candidate will work collaboratively with cross-functional teams to enhance the design and simulation capabilities of our advanced battery systems.

This role is based in Hannover, Germany

Key Responsibilities: What you will do

Multiphysics Modeling & Simulation

• Perform FEA/CFD analysis using LS-DYNA, ANSYS Workbench, Fluent UDFs, and APDL scripting to model thermal runaway, mechanical stress, and failure modes in lithium-ion batteries.

• Develop first-principles thermal/electrochemical models for heat generation, thermal gradients, and cooling efficiency under extreme conditions.

• Simulate mechanical damage (crush, vibration) using fracture mechanics and composite material failure criteria.

Digital Twin Development:

• Support the creation and implementation of digital twins for battery systems to simulate real-world performance and predict outcomes.

• Ensure digital twins are aligned with performance targets and validated against experimental data.

Design Optimization:

• Leverage AI/ML tools to optimize design parameters and improve thermal and mechanical performance.

• Conduct sensitivity analyses and parameter studies to identify critical design variables.

Thermal and Mechanical Design:

• Perform thermal and mechanical simulations to assess design feasibility and performance.

• Collaborate with design engineers to refine and improve designs based on simulation results.

Collaboration and Reporting:

• Work closely with cross-functional teams, including systems engineers and design teams, to align simulation efforts with overall project goals.

• Document methodologies, simulation results, and optimization strategies, and present findings to technical and non-technical stakeholders.

Knowledge, Skills and Abilities: What we look for

Education:

Master’s/PhD in Mechanical, Thermal, or Chemical Engineering (or related field).

Technical Skills:
  - Expertise in ANSYS Workbench, LS-DYNA, Fluent UDFs, APDL, or Abaqus.
  - Proficiency in Python for AI/ML workflows (TensorFlow, PyTorch, scikit-learn).
  - Strong grasp of battery electrochemistry, thermal runaway mechanisms, and composite materials.

Soft Skills:

Collaborative problem-solving, customer-facing communication, and technical writing.

Preferred Skills

- Experience with CFD for conjugate heat transfer in battery packs.
- Familiarity with 3D CAD tools (SolidWorks, CATIA, spaceclaim, discovery) for geometry preprocessing.

- Knowledge of Design Optimization, parametric optimization (Matlab, Discovery Simulation, OptisLang)
- Knowledge of high-performance computing (HPC) for large-scale simulations.

Benefits: What we offer you

As a technology leader with strong brand (i.e. VARTA® and OPTIMA®), Clarios notably lives on the creativity, capability and satisfaction of its employees. Therefore, we offer people with drive and power many good reasons to join us:

• Exciting professional tasks and challenges in a diverse international environment with strong commitment to integrity, values, social engagement and sustainability.

• Arrange your working hours and breaks flexible via our flexible and trust-based working hours model and combine your professional and private life even better according to our mobile work policy and company kindergarten.

• A competitive remuneration package, including additional payments such as holiday, Christmas as well as company pension program.

• Your well-being is very important to us: Take advantage of our preventive health care offers such as fitness center, physiotherapist, modern office environment, healthy canteen, team and company events or hobby clubs.

• Stay fit whilst at the same time positively contributing to our environment: Lease your company bike.

• Our well-advanced onboarding process and buddy program supports you to quickly grow into the position and team. By using the offering in our Internal Learning Academy, LinkedIn Learning and EMEA Mentoring Program you will be able to further grow professionally and personally.

• Last, but not least we support you in relocating and finding a flat in location surrounding if applicable and depending on individual factors.

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About Clarios:

Clarios is the global leader in advanced, low-voltage battery technologies for mobility. Our batteries and smart solutions power nearly every type of vehicle and are found in 1 of 3 cars on the road today. With around 18,000 employees in over 100 countries, we bring deep expertise to our Aftermarket and OEM partners, and reliability, safety and comfort to everyday lives. We answer to the planet with a rigorous sustainability focus – advancing best-in-class sustainability practices and advocating for them across our industry. We work to ensure 100% of our products sold are recyclable, and we recycle 8,000 batteries an hour in our network. You can find more information here (PDF). 

To all recruitment agencies: Clarios does not accept unsolicited agency resumes/CVs. Please do not forward resumes/CVs to our careers email addresses, Clarios employees or any other company location. Clarios is not responsible for any fees related to unsolicited resumes/CVs.

Clarios, LLC is an equal employment opportunity and affirmative action employer and all qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, age, protected veteran status, status as a qualified individual with a disability, or any other characteristic protected by law. For more information, please view EEO is the Law, EEO is the Law (supplement), and Pay Transparency Non-discrimination. If you are an individual with a disability and you require an accommodation during the application process, please email Special.Accommodations@Clarios.com.

A Note to Job Applicants: please be aware of scams being perpetrated through the Internet and social media platforms. Clarios will never require a job applicant to pay money as part of the application or hiring process.