Thermal and Mechanical Simulation Modeling Engineer

Job Description

Job Position: Modeling and Simulation Engineer

Lightergy is seeking a battery modeling engineer that can utilize multiphysics-based electrochemical modeling tools such as ANSYS, COMSOL, MATLAB and Python to assist in the development and innovation of advanced battery cells for grid-level battery energy storage systems (BESS). This role will contribute to process improvement initiatives, identifying bottlenecks and optimization opportunities to enhance the prototype designs and industrial-scale manufacturing workflows. The battery modeling engineer will also assist in the mechanical development of components and sub-systems, which include cell electrodes, sheet metal housings, packaging, cell assemblies and fittings.

Candidates must possess strong technical abilities and enthusiasm to take on responsibilities outside of traditional engineering. This position requires adaptability, as projects evolve rapidly and initiatives may shift based on company needs. This role requires both independent and team-based problem-solving skills. Candidates should be prepared to collaborate with electrical engineers, software developers, and operations teams, taking an active role in product development from concept to field deployment.

Key Responsibilities

· Contribute to a multidisciplinary team as a Modeling and Simulation Engineer

· Ensure designs are robust, fully documented, and supported by theoretical calculations, thermal analysis, and stress analysis

· Conduct Finite Element (FEM), Finite Volume (FVM), and Fine Difference (FDM) Methods as part of high-fidelity battery simulations that evaluate the effects of varying temperatures, rates, and electron distributions on battery cell performance

· Model, simulate and optimize pack-level thermal management systems, analyzing effects of cell-to-cell interactions, thermal runaway propagation, thermal hotspots, mechanical stresses, and cooling strategies

Pre-Requisites / Skills / Experience Requirements:

· Bachelor’s degree in Electrical, Chemical or Mechanical Engineering or a closely related subject covering Mechanical Engineering and Design

· Good working knowledge of FLOEFD or similar MCAD thermal simulation package

· Good working knowledge of CREO, Solidworks, or similar MCAD stress analysis package

· Able to utilize mathematical models such as P2D, NGTK, and ECM from software like ANSYS Fluent/Mechanical and COMSOL

· Understanding of material properties such as diffusion coefficients, thermal/electrical conductivity, interfacial resistance, etc. from experimental and literature data

· Tolerance stack-up analysis to meet the dimensional objectives of the design

· Designing and producing manufacturing drawings using GD&T techniques (Geometric Dimensioning and Tolerance)

· Familiarity with 3D printing and additive manufacturing for prototyping

· Ability to assess and identify the most cost-effective solutions in all design work

· Experience with machine learning techniques, predictive analytics, or high-performance computing (HPC) for large-scale simulations is a plus

Additional Professional Attributes:

· Self-motivated and resourceful, with the ability to work in a fast-paced environment with occasional minimum supervision, while also capable of exchanging (receiving and providing) constructive input with colleagues

· Strong collaboration and team working skills, including cross-functionally, with the ability to establish and maintain effective relationships across all levels

· Excellent analytical and communication skills, both verbal and written, including attention to detail and capability to support decision-making

· Capable of working within multiple complex projects simultaneously, while bringing intellectual curiosity and an enthusiasm for problem-solvingCompany Description

Compact Power Inc.bda Lightergy is a next-generation leading provider of energy storage solutions focused on the innovation of sustainable, scalable, and safe battery systems.

Full-time