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Energy Systems Logo Energy Systems · IT - Software Development

Senior Staff Engine Simulation Engineer

United States, Waukesha · Job Posted March 10, 2026
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Job Description

The Senior Staff Engine Analysis/Simulation Engineer provides engineering input that supports the advancement of the design and performance of internal combustion engines (ICE), through simulation, modeling, and data-driven analysis. This position leverages 1-D & 3-D, CFD, FEA, and machine learning tools to optimize system behavior, reduce emissions, and improve product reliability across a range of applications.

Job Responsibility

  • Lead the development and performance of system-level and component-level simulations using 1-D tools such as GT-SUITE, Matlab/Simulink, Converge, and Ansys Fluent to support engine and generator design and development
  • Conduct CFD and FEA analyses to evaluate thermal, structural, and fluid dynamics performance of mechanical and energy systems
  • Conduct in-cylinder combustion analysis using Converge to aid in optimizing the power cylinder design for combustion efficiency and thermal management
  • Interpret and make recommendations based upon simulation results and collaborate with cross-functional teams through design reviews and technical discussions to guide product development
  • Develop modeling workflows and analysis best practices to improve efficiency and accuracy
  • Document analysis objectives, methods, and results using standardized reporting formats and recommend modifications based upon findings
  • Apply data analysis techniques, including Matlab/Simulink modeling, Python-based scripting and machine learning, to support predictive modeling and performance forecasting
  • Stay informed on relevant technologies, tools, and industry trends to support continuous improvement and recommend changes to best practice based upon findings

Requirements

  • Bachelor of Science Degree in Mechanical or Electrical Engineering or related discipline
  • 10+ years of relevant work experience
  • Previous experience in a Simulation Engineer, Analysis Engineer, or a related engineering discipline
  • Proficiency in 1-D simulation with GT-SUITE
  • Proficient at applying MATLAB/Simulink and Python in engineering analysis and simulation
  • Extensive hands-on experience with GT-xCHEM or CHEMKIN as applied to engine aftertreatment system modeling
  • Proficiency in applying 1-D and 3-D CFD tools to internal combustion engine related systems, including thermal management, lubrication system, crankcase ventilation, combustions phasing, camshaft design, turbochargers, exhaust gas recirculation, and exhaust aftertreatment
  • Proficient in simulating in-cylinder combustion using Converge
  • Proficient with co-simulation environments, including Software-in-the-Loop (SiL) and Hardware-in-the-Loop (HiL)
  • Experience with machine learning and predictive analytics techniques applied to engine performance and emissions modeling
  • Experience with internal combustion engine exhaust aftertreatment system design and specification
  • Strong analytical and problem-solving skills, with a deep understanding of internal combustion engine design, operation, and testing
  • Strong written and verbal communication skills with the ability to clearly interpret and present complex simulation results to technical and non-technical audiences

Nice to have

  • Master’s degree in mechanical engineering, Aerospace Engineering, Computer Science, or a related field of study
  • Expertise in engine and engine system simulation with GT-SUITE
  • Expertise applying MATLAB/Simulink and Python in engineering analysis and simulation to internal combustion engine design
  • Fluency in using Converge to conduct in-cylinder combustion modeling in internal combustion engines
  • Expertise in exhaust aftertreatment simulation with GT-Suite/GT-xCHEM or CHEMKIN
  • Advanced proficiency in applying 1-D and 3-D CFD tools to complex propulsion systems, with demonstrated success in optimizing thermal, lubrication, and ventilation performance
  • Deep expertise in internal combustion engine system architecture, operational dynamics, and advanced testing methodologies
  • Extensive experience designing and executing co-simulation workflows, including SiL and HiL integration for real-time system validation
  • Exceptional ability to synthesize and present complex simulation insights to diverse technical and non-technical stakeholders, influencing design decisions
  • Proficient in applying machine learning and advanced predictive analytics to optimize engine performance and emissions, with experience developing custom models
  • Superior analytical acumen and strategic problem-solving capabilities, with a track record of delivering high-impact engineering solutions
  • Excellent written and verbal communication skills with the ability to clearly interpret and present complex simulation results to technical and non-technical audiences
  • Familiarity with gaseous fuel systems for internal combustion engines
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