Senior Thermal Engineer (Lead)

We are looking for an experienced thermal engineer to play a central role in the architecture, design, and validation of Generac's clean energy products, with a strong emphasis on innovative thermal solutions across power electronics and energy storage systems. Roles and Responsibilities Architect, design, model, and validate thermal solutions for Energy Storage Systems (ESS) and power electronics Build CFD models and instrumented thermal test vehicles to validate designs against simulation Create thermal solutions that balance performance, form, and function across the product portfolio Optimize designs for thermal performance, DFM/DFA, acoustics, size, reliability, and cost Provide clear, actionable thermal design guidance to cross-functional engineering teams Size and select components for passive, forced-air, liquid, and two-phase thermal solutions Manage thermal supplier relationships, supporting component selection, validation, and integration Partner with validation and reliability teams to define thermal test parameters and acceptance criteria Collaborate with software and firmware teams to establish thermal policies for control algorithms Minimum Qualifications Bachelor's degree in mechanical engineering or a related field Minimum 7 years of hands-on experience in thermal design and electronics cooling Willingness to travel up to 30%, including international travel Knowledge, Skills, and Abilities Expert-level knowledge of heat transfer, thermodynamics, and fluid mechanics Expertise modeling passive cooling, forced-air, liquid cooling, two-phase systems, battery thermal behavior, and solar radiation Proficiency sizing and selecting fans, radiators, heat sinks, heat pipes, and related components Experience with instrumentation and data acquisition methods for thermal validation Expert proficiency in Ansys, Flotherm, Star-CCM+, or a comparable CFD package Preferred Qualifications Master's degree in mechanical engineering with a specialization in heat transfer Demonstrated record of bringing thermally complex products from development into volume production Experience with thermal solutions for outdoor NEMA/IP-rated products Background in validation testing, product reliability, and failure analysis Proficiency with 3D CAD tools (Creo or SolidWorks preferred) Experience designing thermal solutions specifically for battery energy storage systems Familiarity with battery pack failure modes, including thermal runaway, outgassing, and propagation Working knowledge of UL 9540A regulatory requirements and associated testing Excellent written and verbal communication skills