Process engineer Jobs in Concord, NC

ERS Thermal Engineer - Onsite

GM Performance Power Units (GM PPU) is seeking an ERS Thermal Engineer with a Formula 1 background to join our engineering team in Concord, NC. This role focuses on thermal management for Motor Generator Unit – e-motor (MGU), Control Unit Kinetic – inverter (CU-K), and Energy Store – battery (ES) systems in F1 power units. The engineer will deliver cooling strategies ensuring performance, reliability, and FIA compliance under extreme conditions.

Key Responsibilities

• Design cooling systems for MGU-K, CU-K, and ES, including heat exchangers, interfaces, and fluid routing.
• Perform thermal simulations using STAR-CCM+, ANSYS, or equivalent for CFD/CHT analysis.
• Analyze telemetry data to optimize thermal performance across duty cycles.
• Collaborate with ERS, electronics, mechanical, and integration teams for system packaging.
• Support prototype testing (dyno, track, thermal cycling) and validation.
• Ensure DFM with suppliers for manufacturability and regulatory compliance.
• Document thermal models, results, and trade-offs for review.

Required Qualifications

• Bachelor's degree in Mechanical or related field; Master's preferred.
• 3+ years in thermal management, preferably motorsport or high-power electronics.
• Proficiency in CFD/thermal tools (STAR-CCM+, ANSYS, SimScale).
• Strong heat transfer knowledge for electric motors, power electronics, batteries.
• Experience with materials and processes for extreme environments.
• Familiarity with F1 ERS regulations.

Preferred Qualifications

• Specific F1 ERS thermal design (MGU-K, CU-K, ES).
• Advanced cooling (oil spray, immersion, phase change).
• Thermal interface optimization and packaging in tight constraints.
• Telemetry analysis and controls integration.

Personal Attributes

• Results-driven under aggressive timelines.
• Innovative problem-solver balancing trade-offs.
• Excellent cross-functional communicator.
• Detail-oriented with continuous improvement mindset.
• Passionate about F1 technology.

Ready to be part of a team that pushes boundaries both on and off the track? At GM Performance Power Units, we are developing a new era of performance for the Formula 1 grid. Joining us means entering a startup racing environment backed by a legacy of engineering excellence, giving you the rare opportunity to help build a world-class program from day one. We believe in rewarding innovation and powering potential. As part of our team, you'll benefit from a competitive and comprehensive package designed to support your performance, well-being, and future, helping you thrive at every level.

That includes access to:

• Bonus scheme
• Private healthcare
• 401(k) plan including company match
• Employer-paid life insurance and disability coverage
• 32 days annual leave (including holidays)
• Free financial advisor access
• Employee Assistance Programs (EAP)
• Subsidized on-site dining
• On-site gym
• Discounted GM vehicle purchase/lease program
• Free on-site EV charging for personal GM vehicles

It's all part of our commitment to creating a workplace that's as high-performing and forward-thinking as the people who make it succeed.

Join us and help power what's next. You'll play a pivotal role in ensuring the reliability and performance of a next-generation Formula 1 power unit. Our culture rewards precision, innovation, and the relentless pursuit of performance.

GM Performance Power Units and all affiliated companies are Equal Opportunity employer(s). Minorities, women, veterans, and individuals with disabilities are encouraged to apply. For more information regarding the EEOC, please visit https://www.eeoc.gov/employers/upload/poster_screen_reader_optimized.pdf.

Only direct hires need apply to or inquire about job postings at GM Performance Power Units. We are not accepting calls, resumes or applications from recruiting firms at this time.