Note: The job is a remote job and is open to candidates in USA. Form Energy is seeking a Senior Mechanical Design Engineer – Fluids Analysis to support the development and commercialization of its multi-day energy storage systems. The role leads fluid dynamics and thermal modeling, validates simulations against experimental data, and translates findings into system-level design decisions and engineering practices.
Responsibilities
- Develop and execute high-fidelity CFD simulations and transient thermal models across multiple physical scales, from microscale electrochemical cell fields to macroscale containerized energy storage systems
- Model complex fluid flow and heat transfer phenomena within electrolyte, thermal management, hydrogen, and air delivery systems
- Evaluate system-level thermal-fluid performance to support architectural decisions and detailed mechanical design
- Select appropriate simulation methodologies, numerical approaches, and modeling assumptions based on engineering requirements
- Analyze fluid routing, pressure drops, flow distribution, and cooling loop efficiency
- Investigate conjugate heat transfer, multiphase flow, and closed-loop cooling system performance
- Identify thermal hot spots, flow maldistribution, and potential thermal-fluid risks
- Recommend design improvements to optimize thermal performance, fluid delivery, and overall system efficiency
- Validate physics-based simulation models against experimental measurements and physical test data
- Collaborate with test and instrumentation teams to investigate discrepancies between simulated and measured performance
- Evaluate mesh quality, boundary conditions, material properties, and numerical assumptions to improve model accuracy
- Establish confidence in simulation results through verification, sensitivity analysis, and experimental correlation
- Develop automated simulation and optimization workflows to evaluate design alternatives efficiently
- Use Python or MATLAB to automate post-processing, data visualization, parameter studies, and analysis of large multiphysics datasets
- Identify limitations in existing modeling tools and develop customized solutions to address complex engineering challenges
- Improve simulation efficiency, reproducibility, and scalability across engineering projects
- Partner with mechanical, electrochemical, and power electronics engineering teams to resolve complex thermal-fluid challenges during product integration
- Translate simulation findings into actionable engineering requirements and system-level design recommendations
- Evaluate technical trade-offs between modeling fidelity, computational cost, development timelines, and system performance
- Communicate technical findings and recommendations effectively to multidisciplinary stakeholders
- Establish standardized modeling methodologies, simulation workflows, and technical best practices
- Lead or contribute to peer design reviews to ensure simulation quality and engineering rigor
- Identify emerging technical risks and proactively investigate complex physical phenomena
- Exercise independent engineering judgment when selecting modeling strategies and evaluating simulation results
Skills
- Bachelor's degree with 5+ years of relevant experience , a master's degree with multiple years of relevant experience, or a PhD focused on thermal-fluid sciences with relevant industry experience
- Strong hands-on experience with commercial CFD software, such as:
- Ansys Fluent
- Siemens STAR-CCM+
- COMSOL Multiphysics
- Strong understanding of fluid dynamics, heat transfer, and computational modeling
- Practical experience with conjugate heat transfer (CHT), transient thermal analysis, multiphase flow, and closed-loop cooling systems
- Experience with mesh generation, boundary condition selection, numerical methods, and simulation model setup
- Proficiency in Python or MATLAB for simulation automation, data processing, post-processing, and visualization
- Demonstrated experience validating simulation results against experimental data or physical testing
- Ability to interpret complex simulation results and convert them into practical engineering recommendations
- Strong analytical thinking, problem-solving, and technical communication skills
- Ability to collaborate across disciplines and work effectively in technically complex, evolving engineering environments
- Battery systems, electrochemical systems, or long-duration energy storage
- Hydrogen delivery systems, electrolyte circulation, or air delivery systems
- Thermal management of complex electromechanical or energy systems
- Multiscale modeling, multiphysics simulation, and system-level thermal-fluid optimization
- Automated design optimization, parametric studies, and simulation workflow development
- Experimental instrumentation, thermal testing, and CFD model correlation
- Developing custom engineering tools to improve simulation workflows and technical decision-making
Benefits
- Relocation assistance is available for this opportunity.
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