Physical Design Engineer Intern Jobs in Rochester, MI

ABOUT SLATE

At Slate, we're building safe, reliable vehicles that people can afford, personalize and love-and doing it here in the USA as part of our commitment to reindustrialization. The spirit of DIY and customization runs throughout every element of a Slate, because people should have control over how their trucks look, feel, and represent them.

| WHO WE ARE LOOKING FOR

We are seeking a highly skilled EV Thermal Systems Engineer Intern to lead the design, development, and optimization of advanced thermal management systems for next-generation electric vehicles. In this role, you will play a critical part in ensuring optimal temperature control for high-voltage battery packs, power electronics, electric motors, cabin thermal management and other components to maximize performance, safety, battery life, efficiency, and driving range.

| WHAT YOU GET TO DO

The ideal candidate brings Ph.D.-level expertise in thermal-fluid sciences, multiphase flows, CFD simulation, experimental validation, and prototype development. You will combine simulation-driven design with hands-on prototyping and system-level integration to deliver innovative, efficient, and reliable thermal solutions in a fast-paced EV development environment.

• Design, develop, and optimize advanced thermal management systems for electric vehicles, including liquid cooling loops, cooling plates, manifolds, heat exchangers, spray/immersion cooling concepts, and integrated HVAC/heat pump architectures to maintain optimal temperatures for high-voltage battery packs, power electronics, electric motors, cabin management and other components across diverse ambient conditions, duty cycles, and DC/AC charging scenarios.
• Perform high-fidelity CFD simulations (single-phase and multiphase) using tools such as ANSYS Fluent and GT-SUITE to analyze heat transfer, fluid dynamics, flow uniformity, pressure drops, droplet/film interactions, and air entrapment. Validate models against experimental data to predict and improve thermal performance, reduce hot spots, prevent thermal runaway, and enhance overall system efficiency and vehicle range.
• Lead prototype development and hands-on experimental validation, including CAD design (Creo/SolidWorks), fabrication of thermal components (e.g., atomizers, manifolds, or heat recovery systems), high-speed imaging, flow visualization, droplet size analysis, and thermal testing to evaluate spray performance, heat dissipation, and system robustness under real-world conditions.
• Provide build and production support for thermal systems, including hands-on assembly oversight, system integration on vehicle prototypes or production lines, issue resolution during builds, and coordination with manufacturing teams to ensure design intent is achieved. Perform electrical troubleshooting of thermal control systems, sensors, wiring harnesses, pumps, valves, and controllers to diagnose and resolve integration or performance issues quickly.
• Identify and optimize heat-loss pathways and recovery opportunities using combined CFD and experimental methods to improve overall thermal system efficiency, reduce energy consumption, and extend EV driving range.
• Apply aerodynamic and fluid mechanics principles to optimize airflow in cooling ducts, underbody components, and heat exchangers, balancing thermal requirements with vehicle-level drag reduction and flow uniformity.
• Define system requirements, conduct Failure Mode and Effects Analysis (FMEA), and support risk mitigation for thermal architectures. Collaborate with cross-functional teams (battery systems, powertrain, HVAC, manufacturing, and suppliers) to ensure seamless integration, packaging, cost-effectiveness, and compliance with performance, safety, and regulatory standards.
• Take full ownership of thermal component release activities in Windchill, including preparation and management of engineering change orders (ECOs), BOMs, drawings, and documentation to support timely product releases and manufacturing handoff.
• Take full ownership of thermal component release activities in Windchill, including preparation and management of engineering change orders (ECOs), BOMs, drawings, and documentation to support timely product releases and manufacturing handoff.

| WHAT YOU BRING TO THE TEAM

• Pursuing a Bachelor Degree, Masters Degree, or PhD in (Electrical, Mechanical, Automotive Engineering)
• Must be able to work full-time (40 hours per week).
• Must have at least a 3.0 GPA.
• Junior level or higher
• Strong problem-solving and analytical skills with a data-driven approach.
• Excellent collaboration and communication skills for cross-functional teamwork.
• Ability to thrive in a dynamic, fast-paced environment and manage multiple priorities.
• Passion for electric vehicle technology and sustainable mobility.
• Experience/knowledge in thermal management systems is a plus.

WHY JOIN TEAM SLATE?

At Slate, we're fueled by grit, determination, and attention to detail. The start-up spirit of ingenuity and resourcefulness move our business forward. Team Slate fosters a culture of excellence, innovation, and mutual respect, and is motivated by shared principles.

• Safety First

• Delight Customers

• One Team

• Relentless Improvement

• Fast, Frugal, and Scrappy

• Respectful Collaboration

• Positive Legacy

WE WANT TO WORK WITH PEOPLE THAT REFLECT THE COMMUNITIES IN WHICH WE OPERATE.

Slate is proud to be an Equal Employment Opportunity and Affirmative Action employer. We do not discriminate based upon race, color, religion, gender, gender identity or expression, sexual orientation, national origin, genetics, disability, age, veteran status, marital status, parental status, cultural background, organizational level, work styles, tenure and life experiences. Or for any other reason.

Slate is committed to providing reasonable accommodation for qualified individuals with disabilities in our job application procedures. If you need assistance or an accommodation due to a disability, you may contact us at

slate-talent_acquisition@slate.auto.