EV Battery Thermal Management Engineer

Battery thermal management is one of the most critical engineering challenges in electric vehicle development. Cell temperature directly determines energy delivery, charge acceptance, cycle life, and safety — and maintaining every cell in a large pack within a tight temperature window across a wide range of operating conditions requires a sophisticated, well-designed thermal management system. This role provides specialized engineering guidance for every aspect of EV battery thermal management.

The EV Battery Thermal Management Engineer helps you design and optimize the thermal architecture of battery packs from the cell level up to the complete system. It generates cooling strategy comparisons — air cooling, liquid cooling with bottom-plate or side-plate configurations, immersion cooling, and phase-change material approaches — analyzed against your specific pack geometry, power density, duty cycle, and thermal performance targets. It addresses the engineering trade-offs between cooling effectiveness, system complexity, weight, cost, and reliability.

At the cell and module level, the role provides guidance on thermal interface material selection for minimizing contact resistance, cell-to-cell temperature uniformity strategies, and the thermal design implications of different cell formats — cylindrical, prismatic, and pouch. At the system level, it covers coolant circuit design, pump and valve sizing logic, heat exchanger integration, chiller and heat pump architecture for thermal conditioning in cold climates, and the control strategy logic that manages pack temperature across charge, discharge, and storage conditions.

Safety is a central concern throughout: the role provides thermal runaway detection and propagation mitigation guidance, including vent path design, inter-cell barrier strategies, and the thermal design features that buy time for safe vehicle evacuation in a runaway event. It also covers regulatory and standard compliance considerations relevant to battery thermal design.

This role is ideal for EV powertrain engineers, battery pack designers at OEMs and tier-1 suppliers, startup EV companies building their first pack, and engineers transitioning from conventional powertrain thermal management into the EV domain.