Thermal Engineer

Job Title: Thermal Simulation Engineer Job Description This role focuses on developing and applying advanced thermal and structural simulation models to optimize product designs and manufacturing processes, with a particular emphasis on current‑carrying products such as connectors, busbars, and cable assemblies. You will work closely with design, manufacturing, and testing teams to validate simulations, solve complex thermo‑mechanical issues, and drive data‑driven improvements in product performance, reliability, and cost efficiency from concept through production. Responsibilities • Lead the development and implementation of complex thermal simulation models to optimize product designs and manufacturing processes, especially for current‑carrying products including connectors, busbars, and cable assemblies. • Perform detailed calculations and simulations on temperature distribution across systems to assess thermal performance, heat transfer, and reliability. • Conduct thermo‑mechanical and structural simulations to support design optimization, material selection, and validation throughout the product lifecycle from concept to production. • Simplify complex CAD geometries to enable efficient and accurate structural and thermal simulation analyses. • Apply in‑depth knowledge of mechanical design, conductive and convective heat transfer, and fluid flow mechanics to build robust simulation models. • Collaborate with design, manufacturing, and testing teams to correlate FEA results with physical test data and refine models and designs accordingly. • Use Design of Experiments (DOE) and optimization techniques to systematically improve designs and processes based on simulation outcomes. • Direct cross‑functional teams to address and resolve intricate design and manufacturing issues identified through simulations and testing. • Analyze complex simulation results to identify performance gaps and improvement opportunities, and drive design or process changes to address them. • Ensure simulation models are maintained, updated, and enhanced to preserve accuracy, relevance, and alignment with evolving product and process requirements. • Validate concept designs using simulation techniques to determine design robustness and confirm that critical functional requirements are met. • Deploy FEA techniques using implicit and explicit approaches with tools such as Ansys Workbench, LS‑DYNA, HyperMesh, Simufact, Moldex3D, OptiSLang, Icepak, Maxwell, and Ansys HFSS. • Translate real‑world engineering problems into appropriate finite element analysis (FEA) models, interpret analysis results, and select optimal solutions, including linear and non‑linear analyses under multiple physics domains. • Monitor and evaluate simulation software capabilities and industry trends, recommending improvements or new tools to enhance analysis workflows. • Collaborate closely with design and validation teams to enhance design optimization and ensure simulation insights are integrated into product development. • Consider the financial impact of design and process decisions, using simulation results to support cost‑effective and value‑driven solutions. • Apply knowledge of associated manufacturing processes such as molding, stamping, plating, crimping, and assembly to build realistic models and interpret results. • Incorporate understanding of soldering, crimping, and welding technologies into simulation and design recommendations. • Utilize expertise in CAE tools, optimization techniques, and testing methods to correlate test and simulation data and continuously improve model fidelity. • Implement LEAN, Six Sigma, and Kaizen techniques in live projects to streamline workflows, reduce waste, and improve quality. • Support technical paper publications and patent applications by generating high‑quality simulation data, analysis, and documentation. Essential Skills • Bachelor’s degree (BE/B.Tech) in Mechanical or Electrical Engineering. • 3–5 years of industry experience in thermal, structural, or simulation engineering. • Strong expertise in Ansys Workbench for FEA‑based thermal and structural simulations. • Hands‑on experience with thermal simulation of current‑carrying products such as connectors, busbars, and cable assemblies. • Proficiency in mechanical design principles and product design processes and methodologies. • In‑depth understanding of conductive and convective heat transfer and fluid flow mechanics. • Proficiency with FEA tools including ANSYS Workbench, LS‑DYNA, HyperMesh, Simufact, Moldex3D, OptiSLang, Icepak, Maxwell, and Ansys HFSS. • Experience with system simulation tools such as MATLAB and Simulink. • CAD proficiency with tools such as PTC Creo and SpaceClaim, including the ability to simplify complex geometries for analysis. • Strong skills in CAE tools, optimization techniques, and testing methods, including correlation of test and simulation data. • Knowledge of material science, including metals, resins, and hyperelastic materials, and their implementation in simulations. • Experience working with connector products, including plastic and sheet metal parts. • Ability to translate real engineering problems into FEA models, perform linear and non‑linear analyses, and interpret multi‑physics results. • Proficiency with programming or scripting languages such as Python and Microsoft VBScript. • Solid command of MS Office tools for documentation, reporting, and data analysis. Additional Skills & Qualifications • Master’s degree (M.Tech) in Mechanical or Electrical Engineering is preferred. • Experience with DOE (Design of Experiments) and advanced optimization techniques to improve designs and processes. • Familiarity with Power BI or similar tools for data visualization and performance reporting. • Knowledge of associated manufacturing processes including molding, stamping, plating, crimping, and assembly. • Understanding of soldering, crimping, and welding technologies and their impact on product performance. • Experience correlating test and simulation results to refine models and improve predictive accuracy. • Background in implementing LEAN, Six Sigma, or Kaizen methodologies on live engineering projects. • Exposure to technical paper writing and supporting patent applications through robust simulation and analysis. • Ability to work effectively in cross‑functional teams, communicating complex technical concepts in a clear and accessible manner. • Strong analytical, problem‑solving, and decision‑making skills with a data‑driven mindset. Work Environment You will work in a collaborative engineering environment that combines advanced simulation tools, CAD systems, and testing facilities to support end‑to‑end product development. The role involves close interaction with design, manufacturing, validation, and testing teams, with frequent use of FEA platforms such as Ansys Workbench, LS‑DYNA, HyperMesh, Simufact, Moldex3D, OptiSLang, Icepak, Maxwell, and Ansys HFSS, as well as system simulation tools like MATLAB and Simulink. CAD work is primarily performed in PTC Creo and SpaceClaim, and you will regularly use Python, VBScript, MS Office, and data visualization tools such as Power BI to analyze and present results. The environment emphasizes continuous improvement through LEAN, Six Sigma, and Kaizen practices, encourages technical innovation and publication, and supports close integration between simulation, testing, and manufacturing to deliver robust, high‑performance products. 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. Requirements 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) Workplace Type This is a fully onsite position in Middletown,PA. Application Deadline This position is anticipated to close on Jul 20, 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 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. 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