Sr. Product Development Engineer

Job Title: Senior Product Development Engineer – Fulltime Onsite, Novi MI

ThermoLift is seeking a highly motivated and detail-oriented Product Development Engineer - Level II with a strong background in thermodynamic systems, mechanical design, modeling, testing, and analysis. This role will be responsible for the end-to-end development of Thermolift’s heat pump components and systems, ensuring quality, performance, and compliance with industry standards.

The ideal candidate will have expertise in reliability strategies (FEA & CFD), computational system modeling, and prototype validation, working collaboratively with engineering, testing, and manufacturing teams to ensure the highest performance and reliability of our product. This role is crucial for pushing the boundaries of advanced thermal and mechanical system designs and will have a direct impact on the success of our technology in the market. Apply Now: https://thermoliftsolutions.com/careers/

Key Responsibilities:

Design & Development

Lead the design and development of mechanical systems, products, and equipment from concept to production.

Develop and implement design standards, methodologies, and best practices to ensure high-quality, manufacturable designs.

Perform FEA (Ansys, SolidWorks) and CFD (Ansys Fluent) analysis to simulate system behavior to enhance and predict system performance.

Develop custom mathematical models to optimize system performance using tools like MATLAB, MathCAD, or Python.

Ensure compliance with industry standards, codes, and safety regulations (ANSI, ASHRAE, UL, etc.).

Prototype & Testing

Develop and execute test plans for HVAC systems and components to meet regulatory and performance standards.

Utilize LabView, data acquisition systems, and advanced sensor technologies to monitor and analyze component performance.

Oversee component testing, fatigue analysis, and failure investigations.

Perform Failure Mode and Effect Analysis (FMEA) and recommend reliability strategies to prevent failures.

Cross-functional Collaboration

Work with manufacturing, supply chain, and external vendors to transition designs from prototype to production.

Support intellectual property development through patent contributions and research publications.

Innovation & Continuous Improvement

Stay at the forefront of thermodynamics, materials science, and mechanical engineering advancements.

Apply data-driven design methodologies to improve product efficiency and reliability.

Recommend and implement changes to products, processes, or business practices to drive continuous improvement 

Minimum Qualifications

●    Master’s Degree in Mechanical Engineering.

●    8 years of experience in product development or similar fields.

●    3 years of experience with FEA or CFD using tools like Solidworks and Ansys

●    Proficiency in analysis software (MathCAD, MATLAB, Python, etc.).

●    Experience with component testing, LabView, data acquisition systems, and results analysis.

●    Hands-on experience with prototype development, performance testing, and failure analysis.

●    Ability to travel within the U.S./Midwest up to 20%.

Preferred Qualifications

●    Ph.D. in Mechanical Engineering with a focus on thermodynamics, heat transfer, or energy systems.

●    Experience developing and manufacturing regenerators for thermodynamic systems

●    Knowledge of HVAC, gas heat pumps, or Stirling/Ericsson cycle systems.

●    Experience in startup environments or high-impact R&D roles.

●    Strong knowledge of design for manufacturing (DFM) and design for reliability (DFR).

●    Experience with patent development and research publications.

This is a full-time, on-site position requiring frequent hands-on interaction with the ThermoLift product and components. Candidates must reside within a commutable distance from Novi, MI and can apply at: https://thermoliftsolutions.com/careers/