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.

Company Overview

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