Staff Engineer - Simulation & Validation

What We Offer

• At Rehlko, our Total Rewards programs are designed to accelerate growth, energize performance, and support a culture of inclusion at every stage of life and work.
• We offer total rewards that are easily understood, recognize results, enable career mobility, and reflect our commitment to valuing diverse needs in a fast-moving world.
• We provide:

• Competitive compensation and benefits
• Work-life flexibility
• Recognition and rewards
• Development and career opportunities
• A safe and inclusive workplace

Why You Will Love this Job

The Staff Engineer, Simulation & Validation, is responsible for leading thermal and fluid flow simulation activities and validating analytical results through experimental testing. This role supports the development and optimization of engine thermal management systems, power electronics cooling solutions, fuel delivery systems, and exhaust systems.

The ideal candidate will bring expertise in Computational Fluid Dynamics (CFD), heat transfer, and thermal systems design while collaborating across engineering, testing, manufacturing, and supplier teams to improve product performance, durability, and customer satisfaction. This position directly influences engine cooling system performance, generator thermal management solutions, power electronics cooling strategies, fuel and exhaust system optimization, product validation methodologies, and future simulation capabilities and engineering best practices.

• Work mode: Hybrid-2-3 days a week
• Work Location: N7650 County Rd LS, Sheboygan, WI, 53083.
• Applicants must be authorized to work in the US without requiring new or transfer visa sponsorship now or in the future.

Key Responsibilities

• Lead thermal and fluid flow simulations to evaluate and optimize cooling system performance using CFD tools, including Siemens STAR-CCM+ and comparable technologies.
• Analyze and optimize engine thermal management systems, including radiators, fans, airflow distribution, cooling packages, and related components.
• Perform simulation and validation activities for fuel delivery, exhaust, and thermal management systems to ensure design and performance targets are achieved.
• Design, evaluate, and optimize heat transfer solutions for power electronics and related applications.
• Develop analytical methods, processes, and optimization tools that improve thermal system performance, robustness, and cost effectiveness.
• Conduct experimental testing and data analysis to correlate simulation models with physical validation results.
• Partner with product development engineers, laboratory teams, suppliers, and cross-functional stakeholders to solve complex engineering challenges.
• Develop and publish technical reports, engineering standards, validation procedures, best-practice guidelines, and technical documentation.
• Research and evaluate emerging simulation technologies and tools, recommending new capabilities that enhance engineering effectiveness and product performance.

Required Qualifications

• Bachelor's degree in mechanical engineering or a related engineering discipline.
• Minimum of six (6) years of engineering experience in thermal systems, fluid dynamics, simulation, validation, or related technical disciplines. Graduate-level research may be considered toward experience requirements.
• Demonstrated experience applying Computational Fluid Dynamics (CFD) tools to solve complex engineering problems.
• Strong understanding of heat transfer, thermodynamics, fluid flow, thermal management, cooling systems, and related engineering principles
• Experience developing simulation models and validating analytical predictions through testing and experimentation.
• Effective technical communication skills, including the ability to present findings and recommendations to technical and non-technical audiences.

Preferred Qualifications

• Master's degree or PhD in Mechanical Engineering, Thermal Sciences, Fluid Dynamics, Heat Transfer, or a related field.
• Experience with Siemens STAR-CCM+ or similar CFD software.
• Experience supporting engine cooling systems, power generation equipment, power electronics cooling, heat exchangers, or thermal management systems.
• Experience correlating simulation models with laboratory and field validation data.
• Experience authoring technical papers, engineering standards, best practices, or white papers.

Additional information

This is an opportunity to contribute to the development of innovative products while working alongside talented engineering professionals on highly visible and technically challenging projects.

Pay and benefits

The Salary range for this position is $98,900.00-$125,600.00.The specific Salary rate offered to a candidate may be influenced by a variety of factors including the candidate's experience, their education, and the work location.

Americans with Disabilities Act (ADA)

It is the policy of Rehlko to comply with all applicable provisions of the Americans with Disabilities Act (ADA) and corresponding national, state, local, or other applicable laws. Rehlko will not discriminate against any qualified associate or applicant with respect to any terms, privileges, or conditions of employment because of a person's physical or mental disability. If you have a disability and require an accommodation in the application process or during the course of employment, please contact.