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Crash Simulation Engineer Jobs (NOW HIRING)

eShocan

Sr. Occupant Safety Engineer

Troy, MI · On-site

Sr. Occupant Safety Engineer Position Overview eShocan is seeking an experienced and highly ... Experience in full vehicle crash simulation and system-level optimization * Exposure to correlation ...

Stellantis

CAE Safety Engineer

Auburn Hills, MI · On-site

The Vehicle CAE Safety Engineer is responsible for developing and optimizing vehicle crash safety ... Use simulation results to propose design solutions and structural enablers for ICE, BEV and hybrid ...

Stealth Battery Startup

CAE Engineer

San Jose, CA · On-site

$186K - $265K/yr

... crash and underbody impact. • Build and refine detailed simulation models using CAD and empirical ... S. or M.S. in Mechanical Engineering, Applied Mechanics, or related discipline. • 5+ years of ...

HITEC Sensors

Vinyl Molder of Crash Test Dummies

Huron, OH · On-site

$13.25 - $16.25/hr

... virtual simulation software, integrated crash test systems, precision sensors, specialized fiber optics, and laser-based material engineering. Our highly specialized solutions are used in the ...

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Crash Simulation Engineer information

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$39K

$123.4K

$190.5K

How much do crash simulation engineer jobs pay per year?

As of Jun 1, 2026, the average yearly pay for crash simulation engineer in the United States is $123,399.00, according to ZipRecruiter salary data. Most workers in this role earn between $92,000.00 and $146,500.00 per year, depending on experience, location, and employer.

What are the key skills and qualifications needed to thrive as a Crash Simulation Engineer, and why are they important?

To thrive as a Crash Simulation Engineer, you need a strong background in mechanical engineering or a related field, with expertise in finite element analysis (FEA) and crash dynamics. Familiarity with simulation tools such as LS-DYNA, HyperMesh, and CATIA, along with relevant certifications in simulation software, is highly valuable. Attention to detail, problem-solving, and effective communication skills help convey complex simulation results and collaborate with cross-functional teams. These competencies are essential for ensuring vehicle safety, compliance with regulations, and the successful integration of crashworthiness into the design process.

What are the typical challenges faced by Crash Simulation Engineers when integrating simulation results with real-world crash test data?

Crash Simulation Engineers often encounter challenges in aligning simulation results with actual crash test outcomes due to factors like material variability, model accuracy, and real-world unpredictability. Bridging this gap requires close collaboration with test engineers, iterative refinement of finite element models, and thorough validation processes. Staying updated with the latest simulation software and continually improving modeling techniques are essential to accurately predict crash performance and ensure vehicle safety compliance.

What does a Crash Simulation Engineer do?

A Crash Simulation Engineer uses computer modeling and simulation software to analyze how vehicles behave during collisions. They help predict the impact of crashes on vehicle structure and passenger safety, allowing manufacturers to improve design before building physical prototypes. Their work is crucial for meeting safety standards and regulations, as well as reducing development costs and time. Crash Simulation Engineers often collaborate with design, testing, and safety teams to ensure vehicles are both safe and efficient.

What is the difference between Crash Simulation Engineer vs Finite Element Analyst?

AspectCrash Simulation EngineerFinite Element Analyst
Required CredentialsBachelor's or Master's in Mechanical Engineering, Automotive Engineering, or related fields; knowledge of CAE softwareBachelor's or Master's in Mechanical Engineering, Civil Engineering, or related fields; expertise in finite element analysis software
Work EnvironmentAutomotive or aerospace R&D labs, design teams, testing facilitiesEngineering firms, research institutions, manufacturing companies
Industry UsagePrimarily in automotive safety, crashworthiness, and structural integrityBroadly in structural analysis, product design, and failure prediction

The Crash Simulation Engineer focuses on developing and running crash tests using specialized software to improve vehicle safety. In contrast, the Finite Element Analyst performs detailed structural analyses across various industries. While both roles require knowledge of CAE tools and similar credentials, the Crash Simulation Engineer specializes in crash scenarios, making their work more specific to automotive safety testing.

More about Crash Simulation Engineer jobs
What cities are hiring for Crash Simulation Engineer jobs? Cities with the most Crash Simulation Engineer job openings:
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What job categories do people searching Crash Simulation Engineer jobs look for? The top searched job categories for Crash Simulation Engineer jobs are:
Crash Simulation Engineer jobs near you
Infographic showing various Crash Simulation Engineer job openings in the United States as of May 2026, with employment types broken down into 90% Full Time, 4% Part Time, 4% Contract, and 2% Nights. Highlights an 87% In-person, 11% Hybrid, and 2% Remote job distribution, with an average salary of $123,399 per year, or $59.3 per hour.
Crash/Safety Mechanical & Integration Engineering

Crash/Safety Mechanical & Integration Engineering

Stellantis

Auburn Hills, MI • On-site

Full-time

Posted 9 days ago

Stellantis rating

7.4

Company rating: 7.4 out of 10

Based on 123 frontline employees who took The Breakroom Quiz

17th of 44 rated automakers

Job description

The High Voltage Safety Integration (HVSI) Team is part of the Global Power Electronics Engineering organization and serves as the technical core team for HV safety compliance, mechanical integration compliance, and DC bus integration compliance across all power electronic devices not limited to Inverters, On board chargers, and DC-DC Converters and relevant power electronics component. The team collaborates closely with global power electronics engineering groups, vehicle architecture teams, and suppliers to ensure that HV components are safely packaged, compliant with regulations, and fully integrated into the vehicle environment. The High Voltage Safety Integration Engineer ensures that all electrified vehicle programs meet global safety regulations through robust crash-avoidance design, compliant HV packaging for all HV components, and cross-functional technical integration.
Core Responsibilities:
  • Ensure high-voltage (HV) safety compliance across all electrified vehicle programs through robust design execution, packaging strategies, and crash-avoidance solutions.
  • Lead technical assessment of CAE crash simulations, physical crash test results, and supplier analyses to identify safety risks and drive continuous design improvement.
  • Own HV safety and compliance content within the Product Book, ensuring accuracy, completeness, and on-time delivery in alignment with program milestones.
  • Develop, maintain, and communicate the HV Safety Scorecard for leadership and program reviews, providing clear technical recommendations and program status.
  • Drive cross-functional alignment with Powertrain COE, HV Safety Subsystem teams, Crash Safety, and Vehicle Program Teams to ensure timely implementation of safety requirements.
  • Ensure compliance with global safety regulations (FMVSS 305, ECE R100) and adherence to GM internal HV safety standards and processes.
  • Champion continuous improvement by developing and updating HV safety best practices, lessons learned, and design guidelines across vehicle programs.

Basic Qualifications:
  • Bachelors degree in mechanical, Automotive, Aerospace, Electrical Engineering or related degree field
  • 5 or more years of experience in product engineering, systems engineering, or vehicle safety development within the automotive industry
  • Leading HV safety integration, crash simulation analysis, or crash test correlation activities across multiple vehicle programs
  • Working with suppliers to drive design robustness, implement lessons learned, and ensure compliance with safety and packaging requirements
  • Hands-on experience with electrified vehicle architectures (HEV, PHEV, BEV), including HV component packaging and system integration
  • Interpreting and applying global safety regulations (FMVSS 305, ECE R100) and internal OEM safety standards
  • Familiarity with OEM development processes, program milestones, and cross-functional engineering workflows
  • Strong expertise in CAE crash simulation interpretation, physical crash test analysis, and correlation methodologies.
  • Proficiency in reviewing CAD models, GD&T, connectors, vehicle tree structures, and packaging studies for HV safety integration.
  • Understanding of DFM, DFA, DFMEA, PFMEA, and design-for-service principles.
  • Knowledge of power electronics systems not limited to inverters, chargers, MGUs, HV cables and their integration constraints
  • Familiarity with PLM systems such as Teamcenter and CAD environments used for vehicle packaging
  • Ability to evaluate supplier CAE reports, mold-flow analyses, and durability assessments; manufacturing knowledge of HV components and castings (HPDC)
  • Effective communication and leadership skills to influence cross functional teams and suppliers
  • Self-motivated, detail-oriented, and committed to delivering high-quality, safe, and compliant engineering solutions
  • Demonstrated ability to mentor and develop junior engineers while contributing to continuous improvement and best-practice development
  • High level of ownership, organization, and accountability while managing multiple vehicle programs and deliverables

Preferred qualifications:
  • Masters Degree in Mechanical Engineering
  • Crash Safety experience
  • Printed Circuit Board (PCB) design and fabrication experience
  • Strong expertise in interpretation of CAE crash simulation results, physical crash test data, and CAE-to-test correlation methodologies.

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