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Thermal Engineer Jobs in Rochester Hills, MI (NOW HIRING)

Blue Bird

Senior Thermal Engineer

Troy, MI · On-site

$97K - $134K/yr

JOB SUMMARY The Senior Vehicle Thermal Systems Engineer is responsible for the vehicle-level thermal management strategy for next-generation commercial chassis platform from concept through ...

Blue Bird

Senior Thermal Engineer

Troy, MI · On-site

$97K - $134K/yr

JOB SUMMARY The Senior Vehicle Thermal Systems Engineer is responsible for the vehicle-level thermal management strategy for next-generation commercial chassis platform from concept through ...

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Ford Motor Company

Thermal Systems Engineer

Dearborn, MI

$115K - $192K/yr

As an R&A Thermal Systems Research Engineer, you will pioneer next-generation thermal system components and architectures - engineering energy-efficient, robust, compact, and cost-effective solutions ...

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All JobsThermal Engineer JobsThermal Engineer Jobs in Rochester Hills, MI

Thermal Engineer information

See Rochester Hills, MI salary details

$40K

$96.2K

$154.2K

How much do thermal engineer jobs pay per year?

As of Aug 14, 2026, the average yearly pay for thermal engineer in Rochester Hills, MI is $96,213.00, according to ZipRecruiter salary data. Most workers in this role earn between $73,600.00 and $118,700.00 per year, depending on experience, location, and employer.

What is a thermal engineer?

Thermal engineers are professionals who specialize in the study and application of heat transfer and thermodynamics. They design, analyze, and optimize systems and components that involve heating or cooling processes, such as HVAC systems, engines, electronics, and power plants. Their work is essential in industries like aerospace, automotive, electronics, and energy, where managing temperature is critical for performance and safety. Thermal engineers use advanced simulation tools and mathematical models to solve complex heat-related challenges and improve energy efficiency.

What are the key skills and qualifications needed to thrive as a thermal engineer, and why are they important?

To thrive as a Thermal Engineer, you need a solid background in thermodynamics, heat transfer, and fluid mechanics, typically supported by a degree in mechanical or thermal engineering. Proficiency with simulation and modeling tools such as ANSYS, MATLAB, and CFD software, as well as familiarity with industry standards, is often required. Strong analytical thinking, problem-solving abilities, and effective communication skills help distinguish top performers in the field. These skills are crucial for designing efficient thermal systems, troubleshooting performance issues, and collaborating with multidisciplinary teams to meet project goals.

What is the difference between Thermal Engineer vs Mechanical Engineer?

AspectThermal EngineerMechanical Engineer
CredentialsBachelor's or Master's in Mechanical, Mechanical Engineering, or ThermodynamicsBachelor's or Master's in Mechanical Engineering or related field
Work EnvironmentDesigning thermal systems, heat transfer analysis, HVAC, aerospace, electronics coolingDesigning mechanical systems, structural components, manufacturing processes
Industry UsageElectronics, aerospace, HVAC, energy systemsAutomotive, manufacturing, robotics, aerospace

Thermal Engineers specialize in heat transfer, thermodynamics, and thermal system design, often working on electronics cooling and energy systems. Mechanical Engineers have a broader scope, covering mechanical design, structural analysis, and manufacturing. While both roles require similar educational backgrounds, Thermal Engineers focus more on thermal aspects within various industries, whereas Mechanical Engineers handle a wider range of mechanical systems.

How much do thermal engineers get paid?

Thermal engineers typically earn between $70,000 and $110,000 annually, depending on experience, location, and industry. Entry-level positions may start around $60,000, while senior roles or specialized fields can pay over $120,000. Certifications and proficiency with simulation tools like ANSYS can influence salary levels.

What does a thermal engineer do?

As a thermal engineer, you maintain, create, or repair mechanical systems that involve a heat transfer process into other forms of energy. You analyze how mechanical heat sources interact with different physical and industrial systems. You test various components of heat transfer within a system, which sometimes involves chemical fluids and gas. You may work with large or small-scale heating or cooling equipment, from industrial heaters to airplane engines. Other duties and responsibilities require you to work in locations in need of heat or cooling mitigation, such as a power plant or landfill. Aerospace companies, public utilities, and other industrial firms hire thermal engineers.

What are some common challenges thermal engineers face when designing cooling systems for electronic devices?

Thermal Engineers often encounter challenges such as managing heat dissipation in increasingly compact and high-powered electronic devices, where space for cooling solutions is limited. Balancing performance, efficiency, and cost while ensuring reliability requires careful selection of materials and innovative thermal management techniques. They must also collaborate closely with electrical and mechanical engineers to integrate thermal solutions without compromising overall device functionality. Adapting to rapidly evolving technologies and staying updated on industry standards is essential for long-term success in this role.

What is the role of a thermal engineer?

A thermal engineer designs and analyzes systems to manage heat transfer and temperature regulation in products and processes. They use principles of thermodynamics, heat transfer, and fluid mechanics, often utilizing simulation tools like CFD software, to ensure components operate within safe temperature ranges and improve energy efficiency.
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What cities near Rochester Hills, MI are hiring for Thermal Engineer jobs?

Cities near Rochester Hills, MI with the most Thermal Engineer job openings:

Thermal Engineer jobs near you
Infographic showing various Thermal Engineer job openings in Rochester Hills, MI as of August 2026, with employment types broken down into 67% Full Time, and 33% Contract. Highlights an 100% In-person job distribution, with an average salary of $96,213 per year, or $46.3 per hour.

Senior Thermal Engineer

Blue Bird

Troy, MI • On-site

$97K - $134K/yr

Full-time

Medical, Dental, Vision, Retirement, PTO

Posted 4 days ago

Job description

About Blue Bird Corporation
Blue Bird (NASDAQ: BLBD) is recognized as a technology leader and innovator of school buses since its founding in 1927. Our dedicated team members design, engineer and manufacture school buses with a singular focus on safety, reliability, and durability. School buses carry the most precious cargo in the world - 25 million children twice a day - making them the most trusted mode of student transportation. The company is the proven leader in low- and zero-emission school buses with more than 25,000 propane, natural gas, and electric powered buses sold. Blue Bird is transforming the student transportation industry through cleaner energy solutions. For more information on Blue Bird's complete product and service portfolio, visit www.blue-bird.com.
JOB SUMMARY
The Senior Vehicle Thermal Systems Engineer is responsible for the vehicle-level thermal management strategy for next-generation commercial chassis platform from concept through production launch. T This role is responsible for engine and transmission cooling, HVAC integration, cooling module design, airflow management, coolant routing, fan strategy, thermal controls, and heat rejection performance across demanding commercial vehicle duty cycles. The engineer will make vehicle-level technical decisions that directly affect chassis packaging, durability, serviceability, manufacturing, performance, and launch timing.
Working across propulsion, chassis integration, controls, validation, manufacturing, suppliers, and external engineering partners, this position has significant autonomy to establish requirements, resolve complex trade-offs, and drive technical execution without waiting for layered approvals.
This is a high-accountability role for an experienced thermal specialist who can create solutions from a blank slate, make sound decisions with incomplete information, and own results from concept through production launch.
ESSENTIAL DUTIES AND RESPONSIBILITIES
  • Thermal Architecture Ownership: Define and own the commercial chassis cooling architecture, including engine cooling, transmission cooling, HVAC integration, coolant circuits, airflow management, fan strategy, and thermal protection.
  • Cooling System Development: Design and optimize cooling modules, radiators, charge air coolers, condensers, heat exchangers, pumps, fans, valves, reservoirs, plumbing, and related components.
  • Vehicle-Level Integration: Lead integration of thermal systems into the chassis while balancing heat rejection, packaging, manufacturability, serviceability, durability, cost, and production readiness.
  • Commercial Duty-Cycle Performance: Develop cooling strategies for high ambient temperatures, low-speed operation, extended idle, grade performance, stop-and-go use, heavy payloads, and other severe commercial vehicle conditions.
  • Thermal Analysis & Optimization: Perform and interpret 1D and 3D thermal-fluid analyses to optimize coolant flow, airflow, heat rejection, fan performance, and system efficiency.
  • Thermal Controls Integration: Define requirements and operating strategies for fans, pumps, valves, compressors, protection logic, and thermal derate functions in collaboration with controls engineering.
  • Supplier & External Engineering Direction: Provide technical direction to suppliers and engineering service providers while retaining ownership of requirements, component selection, design decisions, performance, and technical deliverables.
  • Validation & Production Readiness: Develop and execute thermal DVP&R activities through laboratory, dynamometer, environmental, proving-ground, and vehicle testing to confirm readiness for production.
  • Launch & Manufacturing Support: Support prototype builds, pilot operations, production launch, and early manufacturing by resolving packaging, assembly, supplier, and performance issues with urgency.
  • Root Cause & Corrective Action: Lead investigation and resolution of overheating, insufficient heat rejection, coolant imbalance, leakage, airflow recirculation, HVAC deficiencies, thermal derating, and field reliability concerns.
  • Operate in Ambiguity: Create structure and drive execution where requirements, packaging constraints, supplier capabilities, and technical solutions are evolving simultaneously.

KNOWLEDGE, SKILLS AND ABILITIES FOR SUCCESS
  • Deep expertise in commercial vehicle cooling systems, thermodynamics, heat transfer, fluid dynamics, refrigeration cycles, and airflow management.
  • Strong understanding of engine, transmission, HVAC, and auxiliary cooling systems for commercial or heavy-duty vehicle applications.
  • Proven ability to make vehicle-level technical trade-offs involving performance, packaging, durability, serviceability, manufacturing, cost, and launch timing.
  • Advanced experience with cooling module design, heat exchanger sizing, coolant routing, fan systems, thermal controls, and underhood airflow.
  • Proficiency with GT-SUITE, Simcenter Amesim, ANSYS Fluent, Star-CCM+, or equivalent thermal and CFD tools.
  • Experience developing requirements, DVP&R plans, DFMEAs, technical specifications, and system-level validation strategies.
  • Experience instrumenting and testing vehicles using thermocouples, pressure transducers, flow meters, data acquisition systems, and CAN-based tools.
  • Ability to direct suppliers and external engineering partners while maintaining technical ownership and accountability.
  • Strong analytical, troubleshooting, communication, and rapid decision-making skills.

BASIC EDUCATION AND EXPERIENCE REQUIRED
  • Bachelor's degree in Mechanical, Aerospace, or Automotive Engineering or related discipline with emphasis in thermal sciences, heat transfer, or fluid mechanics.
  • 7+ years experience developing vehicle cooling systems, thermal architectures, HVAC systems, or heat rejection solutions for automotive, commercial vehicle, heavy-duty, off-highway, or similarly complex mobile platforms.
  • All candidates must be a U.S. citizen or permanent resident. Candidates must be authorized to work in the United States and will be required to provide proof of employment eligibility at the time of hire.

PREFERRED EXPERIENCE
  • Demonstrated ownership of a major vehicle thermal system from concept through prototype development, validation, production launch, and issue resolution.
  • Experience integrating thermal systems into constrained chassis packaging environments while balancing vehicle-level performance and production requirements.
  • Experience making complex engineering decisions with limited structure, incomplete information, and aggressive program timing.
  • Experience working directly with manufacturing, suppliers, external engineering partners, and cross-functional vehicle development teams.
  • Experience with commercial trucks, buses, vocational vehicles, stripped chassis, body-on-chassis platforms, or incomplete vehicle applications.
  • Experience developing cooling architectures for high-load, high-ambient, low-speed, grade, extended-idle, or severe-duty operation.
  • Experience integrating multiple propulsion or vehicle configurations within a common commercial chassis architecture.
  • Experience with clean-sheet or major redesign vehicle programs operating under aggressive launch timelines.
  • Experience leading supplier technical development, component selection, industrialization, or recovery activities.
  • Master's degree in Mechanical Engineering, Aerospace Engineering, Automotive Engineering, or a related thermal discipline.
  • Experience resolving thermal issues during prototype builds, manufacturing launch, or customer field operation.

WE'RE LOOKING FOR SOMEONE WHO
  • Takes ownership of complex vehicle behavior and controls challenges and drives them to resolution
  • Thrives in ambiguity and enjoys developing new control strategies from a clean sheet
  • Operates with urgency while maintaining strong engineering judgment
  • Thinks in systems and understands how software influences complete vehicle performance
  • Can balance vehicle performance, energy efficiency, emissions, diagnostics, durability, and customer experience
  • Can influence technical direction across cross-functional engineering teams, suppliers, and external engineering partners without direct authority
  • Wants meaningful ownership over how next-generation commercial vehicles perform in the real world

INCLUDES
  • Continued Professional Development
  • Benefits including medical, dental and vision insurance, 14 paid holidays, vacation time and 401k matching

WORK CONDITIONS
The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.
  • Office environment and production environment
  • Must work in a manufacturing environment with exposure to heat, cold and noise
  • Fast-paced production area with moving objects and sheet metal
  • Occasional periods of standing or sitting for extended periods of time
  • You must wear appropriate PPE when and where required
  • Frequent weeks working 40+ hours
  • Frequent communication with people throughout the day

*The specific statements shown in each section of this description are not intended to be all-inclusive. They represent typical elements and criteria necessary to successfully perform the job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions
Blue Bird® is an equal opportunity employer and makes employment decisions on the basis of merit. We strive to have the best available talent in every job based on the Knowledge, Skills and Abilities each person brings. Blue Bird is committed to compliance with all applicable laws providing equal employment opportunities. This commitment applies to all persons involved in Company operations and prohibits unlawful discrimination in all forms.
All candidates must be a U.S. citizen or permanent resident. Candidates must be authorized to work in the United States and will be required to provide proof of employment eligibility at the time of hire.
#LI-Onsite
Equal Opportunity Employer
This employer is required to notify all applicants of their rights pursuant to federal employment laws.
For further information, please review the Know Your Rights notice from the Department of Labor.

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