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Job Title:
CAE Engineer
Position Description:
We are looking for an experienced structural CAE engineer to lead high-voltage battery internals and related system structural design using CAE tools. You will work with battery design and release engineers on cutting-edge battery technologies to ensure the battery functional environment operates within specified conditions. As a collaborative team player, you will create impact by working across the Electrified Powertrain Engineering organization and with key stakeholders of the battery business. Global Electrified Powertrain Engineering Team is a growing team committed to bringing efficiency and value into the battery architecture through close collaboration with global suppliers. Together, our team works to understand our changing world, identify new opportunities, and take action to design and innovate for the future of mobility - vehicles and surrounding experiences.
Skills Required:
Abaqus - Primary FEA solver (required)
HyperMesh - Pre-processing, meshing, and model setup
nCode or fe-safe - Fatigue and durability analysis
Experience Required:
4+ years of experience working with structural components and designs in an engineering environment.
Bachelor's degree in Mechanical or Structural Engineering.
Broad experience using ABAQUS, Hypermesh, ncode or FeSafe and 3DX.
Minimum of 3 years of working in Abaqus performing non-linear FEA, 5 preferred.
Experience Preferred:
5 or more years of experience specifically in CAE structural modeling and simulation analysis techniques using ABAQUS or equivalent, including experience selecting appropriate solution procedures for complex non-linear problems.
M.S. in Mechanical Engineering or equivalent degree.
Working knowledge of ABAQUS, OptiStruct Non-Linear, HyperMesh, HyperView, ABAQUS Viewer, Teamcenter, 3DEXPERIENCE (3DX), or equivalent tools (ANSYS, etc.).
Working knowledge of CAE tools for fatigue assessments such as FEMFAT, nCode, fe-safe, or equivalent.
Strong experience in correlating complex non-linear CAE models with physical test data, including sensitivity analysis and model tuning for improved accuracy.
Extensive knowledge of various structural materials, high-strength material behavior, energy flow theory and analysis methods, fracture mechanics, and crack initiation/propagation.
Working knowledge and experience using CAE pre-processing tools such as HyperMesh or equivalent for geometry cleanup and meshing, and ABAQUS, Nastran, or equivalent for CAE model solving and post-processing.
Proficiency in ABAQUS scripting (Python) for model automation and advanced post-processing.
Familiarity with sheet metal design specifications, sealing design, structural testing setup, and data collection.
Familiarity with thermal-mechanical coupled analysis that considers temperature-dependent material properties, thermal expansion, and effects on structural integrity.
Proven record of innovative applications and ability to introduce new ideas for product development.
Working knowledge of optimization CAE tools such as modeFRONTIER, iSight, HEEDS, Tosca, or OptiStruct.
Experience in physical testing is a plus.
Ability to mentor junior engineers and collaborate effectively as a team player.
Strong verbal and written communication and interpersonal skills.
Experience with variability, robustness, and Six Sigma methodologies.
Education Required:
MASTER'S DEGREE (w/ FEA courses taken)
Additional Information :
***POSITION IS HYBRID / (4 days per week in the office / Monday to Thursday)***
Build 3D battery internal structural analysis CAE models from CAD designs.
Debug complex finite element (FE) models independently.
Perform 3D structural simulations on high-voltage battery packs at the system, subsystem, and component levels to support internal design development, utilizing non-linear FEA codes such as ABAQUS, ANSYS, or OptiStruct Non-Linear, including pre- and post-processing with HyperMesh, HyperView, and ABAQUS Viewer.
Evaluate 3D structural analysis results and provide technical feedback and design direction to vehicle program and battery pack design teams.
Collaborate with vehicle-level teams to obtain boundary conditions for battery pack structural-level simulations.
Partner with battery lab and vehicle-level testing teams; specify instrumentation for data collection; process physical structural test results and use the data to correlate CAE models.
Coordinate with extended overseas CAE teams for meshing and geometric cleanup tasks.
Compile professional, organized, and structured reports detailing completed CAE work, including recommendations and conclusions.