CAE ENGINEER JOB DESCRIPTION

A vehicle program that ships with unresolved fatigue failures or NVH deviations traces the gap, almost without exception, to simulation work that was too slow, too narrow, or never properly correlated to physical test data. The CAE Engineer closes that gap by owning the finite element analysis workflow from model build through program delivery, embedded across body structure, propulsion, and durability domains at OEM and Tier-1 supplier organizations. Scope is wide. The role answers simultaneously to program timing, attribute performance targets, and the structural integrity of components that must survive accelerated duty cycles and real-world road loads.

As the CAE Engineer, you translate physical engineering requirements into validated simulation models that directly inform design decisions across vehicle development programs, covering domains from body-in-white structural assessment to propulsion system fatigue. You will work within a cross-functional attribute team, interfacing with design release, validation, NVH, and safety integration engineers to balance competing structural requirements against mass and cost targets throughout the program cycle.

Career Impact: Delivering simulation work that influences production vehicle architecture gives CAE Engineers recognized standing among OEM program teams and Tier-1 supplier networks, where multi-domain FEA depth is a scarce and valued credential.

Business Impact: When structural or durability simulation is accurate and on schedule, design teams can commit to component freeze with confidence, reducing costly late-stage physical test failures and engineering change orders.

Growth Opportunity: Depth in implicit and explicit solver methodology, combined with exposure to road load data development and multi-scale correlation, positions engineers for senior specialist or lead CAE roles within OEM attribute organizations.

• Execute finite element analysis plans for assigned vehicle programs, coordinating internal resources and supplier deliverables to meet program milestones.
• Build and maintain FEA models for structural, durability, NVH, and crash domains, ensuring correlation to physical test data at component and full-vehicle level.
• Perform topology optimisation to identify structural load paths and develop design enablers that meet performance requirements within mass and cost constraints.
• Validate design proposals against strength, stiffness, and fatigue requirements under static and dynamic loading conditions across vehicle and component levels.
• Collaborate with body structure, NVH, safety, and vehicle dynamics teams to balance competing attribute requirements and develop integrated design solutions.
• Present CAE results, design recommendations, and program status to attribute teams and program management through formal reports and review presentations.
• Mentor junior engineers in CAE methodology, model quality standards, and result interpretation within the team.
• Develop and improve CAE modelling methods, correlation procedures, and process automations to increase analysis speed and robustness.

• Bachelor's degree in mechanical, aerospace, or automotive engineering, or equivalent work experience.
• 3 or more years of finite element analysis experience in an automotive OEM or Tier-1 supplier environment, with hands-on model build and result delivery.
• Demonstrated expertise in implicit linear and non-linear FEA for structural strength, stiffness, and fatigue applications.
• Proficiency in explicit dynamic simulation for crash and durability events including pothole, curb, and extreme duty cycle loading.
• Experience conducting NVH analysis including modal studies, frequency response, and optimization in an automotive vehicle development context.
• Solid understanding of material property inputs including plasticity, fatigue curves, and SN and EN methods for metallic and polymer components.
• Ability to correlate simulation results against physical test data and drive model improvements based on discrepancies.
• Strong written and verbal communication skills with demonstrated ability to present technical findings to cross-functional program teams.

• Master's degree in mechanical, aerospace, or motorsport engineering with specialization in structural simulation or FEA methods.
• Experience developing road load data and applying accelerated duty cycle creation using equivalent damage methods for durability programs.
• Familiarity with topology and parametric optimization workflows applied to body structure or chassis components in a production vehicle program.
• Programming or scripting capability in Python or TCL/TK for simulation process automation and post-processing workflows.

• FEA model correlation accuracy, measured as deviation percentage between simulation and physical test results across validated components.
• Program milestone adherence rate, tracking on-time delivery of CAE deliverables against agreed attribute review gates.
• Design change reduction rate, reflecting how often CAE-recommended solutions are adopted before physical prototype build.
• Number of design variants assessed per program cycle, measuring throughput and analytical coverage of structural proposals.
• Fatigue life prediction accuracy against component bench test results, expressed as ratio of predicted to measured cycles to failure.
• Typical tools: Iplicit and explicit FEA solvers (commonly Abaqus, Nastran, or Optistruct); pre- and post-processing (commonly HyperMesh, ANSA, or HyperView); fatigue analysis (commonly nCode DesignLife).

• Base Salary Range: $85,000 to $125,000 per year depending on experience and location.
• Bonus: Annual performance bonus of 5 to 12 percent of base salary.
• Equity: Stock or RSU grants common at OEM and larger Tier-1 employers.
• Health Benefits: Medical, dental, and vision coverage; employer contribution standard.
• PTO: 15 to 20 days annually plus standard US public holidays.
• Common Perks: Tuition reimbursement, professional development funding, relocation assistance for senior hires.

Figures are estimates based on general US market benchmarks and may be outdated. Adjust based on location, company size, and seniority level.

Employment decisions are made without regard to race, color, religion, sex, national origin, age, disability, veteran status, genetic information, or any other characteristic protected under applicable federal, state, and local law. Candidates requiring a reasonable accommodation during the application or interview process may request one at any time. Employment in this role is contingent on successful completion of a background screening. All applicants must be authorized to work in the United States without sponsorship, unless otherwise specified in the offer.

The CAE Engineer owns the full finite element analysis cycle for assigned vehicle programs, from building and debugging FEA models from NX math data to conducting topology optimisation that identifies architectural load paths. Working within the Product Development Teams, the engineer collaborates with body SMT, validation, NVH, and safety integration engineers to balance structural requirements and deliver mass- and cost-efficient design solutions.

Key Responsibilities

• Create and execute finite element analysis plans for assigned projects and lead CAE suppliers and internal resources to meet program milestones.
• Build CAE geometry or construct and update FEA models from NX math data and debug first-run vehicle structure models.
• Perform and coordinate virtual assessment of designs and compare results to performance requirements.
• Recommend viable design solutions to resolve performance issues with mass and cost efficiency.
• Conduct topology optimisation to identify architectural load paths and implement enablers into the math.
• Interface with body SMT, validation, structure integration, NVH, and safety integration engineers to balance requirements and design solutions.
• Plan and implement test and development programs to enhance CAE capability.
• Recommend and implement process automators and CAE enhancements for modelling software and solvers.
• Prepare virtual assessment presentations for program management and formal CAE report documentation.

Required Qualifications

• 3 or more years of experience in linear analysis (NASTRAN, OPTISTRUCT or equivalent), non-linear analysis (LS-DYNA), and optimisation.
• Thorough understanding of material properties as inputs to CAE analysis.
• Familiarity with a variety of CAE modelling tools including UG-NX CAD and CAE tools.
• Experience in quasi-static non-linear analysis, NVH, durability analysis, and dynamic crash simulation.
• Proficiency with MS Office applications.
• High degree of analytical ability where problems are complex or difficult.
• Strong interpersonal and communication skills to work effectively with business partners toward mutual goals.

Embedded within the propulsion engineering team, the CAE Engineer delivers 3D mechanical, structural, and thermo-mechanical analysis and model validation across propulsion systems including engine, transmission, eAxle, eMotors, battery, and HV power electronics. Working closely with platform design, development, controls, and vehicle attribute teams, the engineer builds integrated simulation models that advance performance, efficiency, and drivability outcomes across the propulsion portfolio.

Core Functions

• Perform 3D mechanical, structural, and thermo-mechanical analysis and model validation for propulsion systems such as engine, transmission, eAxle, eMotors, battery, HV power electronics, intake, and exhaust.
• Conduct modal analysis and fatigue analysis for propulsion systems.
• Collaborate in defining hardware and software specifications for propulsion so that performance, efficiency, and drivability attributes are met.
• Work closely with platform design, development, controls, and vehicle attribute teams to develop integrated simulation models and communication methods.
• Develop propulsion CAE core competencies including tool sets, software, and best practice techniques.
• Build additional propulsion CAE capabilities to bring value-added analysis in-house where possible.
• Develop simulation models to perform robust engineering investigations and use output to influence engineering designs and business decisions.
• Own, develop, and maintain data, model management, and version control systems.
• Prepare and present material for external and internal project status reviews.

Qualifications and Experience

• Experienced in mechanical and structural analysis for propulsion systems using 3D tools such as Abaqus, HyperMesh, OptiStruct, Ansys, Nastran, or equivalent.
• Experience in vibration and fatigue analysis for propulsion systems including engine, ESS, transmission, eAxles, eMotors, and power electronics.
• Experienced in simulation, analysis, and development environments covering model architecture definition, tool-chain setup, data processing, and reporting.
• Knowledge of state-of-the-art propulsion systems simulation and analysis tools, techniques, and processes.
• Knowledge of propulsion systems component testing, instrumentation, logging, fault analysis, and data processing.
• Knowledge of high-performance hybrid and electric powertrains.
• Good level of technical knowledge of vehicle simulation and test methodologies.
• Creative and thoughtful approach to solving engineering problems with good attention to detail.
• PC literate and at ease with MS Office products.

Reporting to the vehicle engineering leadership, the CAE Engineer analyzes strength and fatigue performance of mechanical systems from component to full vehicle level under static and dynamic loading. Partnering with design engineers, test teams, and the vehicle dynamics group, the engineer develops and champions structural solutions that enable systems to operate safely and reliably throughout the vehicle's life.

Primary Duties

• Analyze strength and fatigue performance of mechanical systems from component to full vehicle level under static and dynamic loading.
• Develop feasible structural solutions meeting real-world strength and durability requirements.
• Develop and improve working methods in the CAE team and across vehicle engineering.
• Report and communicate results at all levels including during cross-functional reviews.
• Champion structural solutions that serve strength and durability attribute performance and coordinate with other attributes for best overall performance.
• Collaborate with the vehicle dynamics team to develop, update, and cascade road load data.
• Mentor and support junior engineers to improve working practices in the team.

Education and Experience

• Master's degree in mechanical, aerospace, or motorsport engineering.
• Proven experience delivering real-world structural performance development using simulation, testing, and first-principle methods.
• Expertise in the use of implicit FE solvers (Optistruct, Nastran, Abaqus).
• Expertise in fatigue calculations using SN and EN methods (Ncode).
• Proficient with statistical analysis applied to the creation of material allowable properties based on large sample test data.
• Working understanding of road load data collection and accelerated duty cycle creation with equivalent damage method.
• Experience of multi-scale FE model correlation.
• Vibration analysis and testing experience for deterministic and random excitations.
• Rigorous approach to engineering problems ensuring consistency and traceability of results.
• Experience in crash and NVH simulation is a plus.

Sitting at the intersection of virtual engineering and physical design, the CAE Engineer supports the conceptual development of automotive components and systems using CAE techniques to meet safety and NVH performance targets. Operating across component design teams, PAT teams, and packaging stakeholders, the engineer runs analysis, distills results, and mentors junior members to continuously improve the quality of virtual models.

Duties

• Support the conceptual development of automotive components and systems using engineering knowledge combined with CAE techniques to meet safety and NVH performance targets.
• Run CAE analysis, summarise results, and feed back conclusions to component and CAE lead engineers efficiently.
• Work effectively with design teams to develop and optimise solutions considering multi-attributes within defined deadlines.
• Support projects and teams including feedback of results through design and project reviews.
• Present at design reviews with key stakeholders including COC component design teams, PAT teams, and packaging teams.
• Work with subject matter experts to ensure project documentation is managed and maintained.
• Support continual development of tools and techniques to enhance capability and improve quality of virtual models.
• Mentor and train junior team members and graduates.

Skills and Qualifications

• Relevant degree or equivalent experience in engineering.
• Working knowledge and experience of CAE methodologies.
• Previous experience in safety and NVH component and system level development using CAE to meet defined performance targets.
• Previous experience delivering engineering or analytical projects.
• Competent in the use of explicit and implicit software and associated pre- and post-processing packages including Optistruct, LS-Dyna, Oasys, and Hyperworks.
• Competent in the use of Catia 22x for CAD part viewing and interrogation.
• Proficient in MS Office (Word, Excel, PowerPoint).
• Experience in proposing product modifications to improve designs.
• Experience working within Agile procedures and guidelines.
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A key member of the engineering systems team, the CAE Engineer develops and maintains deep competency in PDM and CAE systems to advise users and manage the full product lifecycle management application landscape. Collaborating across technical and non-technical teams, the engineer administers systems, leads improvement projects, and carries first-line management responsibilities that keep tools standardised and compliant with quality requirements.

Functions

• Develop and maintain deep knowledge and competency of PDM and CAE systems to advise and provide guidance to users.
• Project manage PDM and CAE improvement projects working with the internal team and implementation partners.
• Manage user administration including adding and changing user access and password resets.
• Manage installations and ensure standardisation of properties setup for all users.
• Perform day-to-day PDM support, maintenance, and fault-finding activities.
• Own, maintain, and update drawing, modelling, and document templates and standards.
• Support testing, development, and implementation of new PDM processes to support change.
• Take ownership and responsibility of key product lifecycle management applications including the support and upgrade roadmap.
• Carry out first-line management duties for allocated team including absence management, performance reviews, and training compliance.

Minimum Qualifications

• Formal relevant technical qualification in engineering or information systems.
• Experience working hands-on in a product development or manufacturing environment.
• Experience administering a business IT system.
• Demonstrable effective team leadership competencies with small teams.
• Highly skilled at collaborating with different teams across the business, both technical and non-technical.
• Excellent written, numerical, and verbal communication skills with the ability to communicate well at all levels.

Structural integrity and manufacturing feasibility of body interior systems depend on the CAE Engineer, who builds, runs, and correlates FEA models for door trim, hard trim, IP, console, and overhead components with special focus on injection molding, structural, impact, and curtain airbag deployment simulations. Based within the body interior engineering group and serving as the analytical interface to design and release engineers, the engineer generates root-cause findings and cost-effective design solutions that resolve both performance and manufacturing issues.

Accountabilities

• Build CAE models including meshing, setting, and running for door trim, hard trim, IP, console, and overhead system components with special focus on injection molding, structural, impact, and curtain airbag deployment simulations.
• Make correlation studies between CAE and physical testing.
• Create bill of materials for every CAE model.
• Interpret CAE model results and prepare clear information to share with design and release engineers.
• Generate feasible proposals to solve performance and manufacturing issues.
• Develop cost-effective design solutions that address performance and manufacturing issues.
• Determine root cause of issues applying appropriate engineering quality tools.
• Validate product changes using appropriate engineering CAE tools.
• Prepare status reports on resolution and timing of changes to support management.
• Arrange and participate in meetings for CAE reviews with relevant stakeholders.

Technical Qualifications

• Good engineering fundamentals in solid mechanics, thermoplastic materials, and manufacturing processes with focus on injection molding.
• Knowledge of CAE tools such as Moldflow, Moldex 3D, LS-Dyna, Abaqus, Nastran, Hypermesh, nCode, ANSA, or other commercially available FEA programs.
• Knowledge of CAD tools.
• Knowledge of programming languages, preferably TCL/TK or Python, is a plus.
• Working knowledge of design verification and the FMEA process.
• Strong troubleshooting experience and familiarity with automotive 8D methodology.
• High capacity for analysis and root cause finding.
• Excellent people skills and the ability to interface with several teams.
• Excellent English communication skills, written and oral, and strong presentation skills.

As the CAE Engineer, this role leads the build, assembly, and analysis of FEA models for durability and fatigue requirements at trimmed body, body-in-white, system, and component level. The durability engineering team relies on this work to develop and optimise structures that meet requirements, advance modelling methods, and present globally trusted results to attribute and program stakeholders.

Activities

• Build, assemble, and analyse FEA models for durability and fatigue requirements at trimmed body, body-in-white, system, and component level.
• Develop and optimise structures and components to meet requirements.
• Present results and recommendations to attribute and program teams globally.
• Develop CAE modelling methods and requirements and perform correlation studies with physical test data.
• Develop process improvements to enable faster, more robust analysis.
• Provide support to all other areas of the business where required.

Experience and Qualifications

• MSc or higher education in mechanical engineering or equivalent.
• Extensive and demonstrable experience in the field of durability CAE at an established OEM.
• Thorough understanding of finite element analysis with hands-on experience in solvers such as Abaqus, Nastran, and Optistruct.
• Proficient in geometry preparation and meshing using tools such as ANSA and Hypermesh.
• Experience with pre- and post-processing tools including ANSA, META, Hypermesh, and Hyperview, and fatigue tools such as nCode DesignLife.
• Experience in vehicle-level durability testing and data processing is advantageous.
• Excellent written and spoken communication skills.
• High level of personal motivation with a proactive approach to self-development.

CAE Engineer supports technical project leaders by maintaining state-of-the-art FEA calculation tools and executing all structural analysis for competence center engineering and R&D functions. The work directly supports supplier capability improvement, design change management, and component integration across multicultural and remote engineering locations.

Operational Focus

• Support technical project leaders and maintain state-of-the-art calculation tools including Abaqus and Hypermesh.
• Perform all FEA calculations for technical project leaders and competence center engineering or R&D engineers.
• Standardise FEA calculations to be outsourced.
• Localise modular components and act as technical expert on module component integration.
• Support supplier development and supply technical support to suppliers.
• Follow component engineering change management, replicate into the database system via GPDM.
• Drive design and design change technical review and release prints, and update DFMEA.
• Create new design rules and specifications.
• Support supplier capability improvement and fire-fighting and failure problem solving.

Background and Experience

• Master's degree in mechanical or automotive engineering.
• 3 years of working experience in FEA analysis as a daily job from an engineering function in the automotive industry.
• Component development experience and supplier support experience.
• Experience in shock absorber manufacturing processes and polymer product engineering is advantageous.
• Excellent communication skills in both Chinese and English.
• Very proactive with excellent interpersonal skills.
• Multi-cultural awareness with ability to communicate and coordinate with remote locations.
• Customer and internal client oriented, quality focused, and analytical.

The CAE Engineer owns the creation and maintenance of FEA models for NVH and applies simulation tools including MatLab, ANSYS, and Hypermesh to deliver structural analysis, robustness studies, and hardware-correlated results for the engineering team. Working across internal functions and drawing on 2D tolerance stack-up studies and 3D modelling, the engineer drives continuous product improvement throughout development and serial production.

Role Responsibilities

• Create and maintain FEA models for NVH for internal use.
• Interface internally on simulation results and change requests.
• Apply specific calculation and simulation tools including MatLab, ANSYS, and Hypermesh.
• Carry out structural analysis using standard FE analysis tools, perform hand calculations, and provide engineering conclusions based on analysis data.
• Ensure design robustness through 3D modelling, stress analysis, interface verification, and 2D tolerance stack-up study, and provide design solutions for robustness improvement.
• Correlate simulation based on hardware NVH measurements.
• Drive continuous product improvement and provide troubleshooting support during development and serial production.
• Determine root cause of product failures.
• Generate reports and appropriate documentation.

Professional Experience

• Bachelor's degree in engineering, preferably in mechanical engineering with focus on vibration and acoustics.
• 2 to 3 years of automotive system analysis experience.
• Experience in numerical calculations and software application with specific skills in Hypermesh and ANSYS APDL.
• Experience in Nastran is a plus.
• Knowledge of different material modelling and working with non-linear problems.
• Experience in manufacturing processes such as stamping and casting technologies is a plus.
• Hardware testing knowledge is a plus.
• Extremely high technical comprehension and enthusiasm for advanced technical solutions.
• Distinctive theoretical and analytical competence.

The CAE Engineer delivers CAE support for automotive body structure and trim components, performing implicit linear and non-linear analysis and preparing detailed reports that guide design improvement decisions. Collaborating with responsible engineers and physical test teams, the engineer manages own projects while mentoring junior CAE engineers within an automotive OEM environment.

What You'll Do

• Provide CAE support for automotive body structure and trim components.
• Discuss analysis model input, loading, and constraints as required with responsible engineers.
• Interface with physical test engineers to gather correlation data as required.
• Prepare CAE models from CAD or existing models.
• Perform CAE analysis including implicit linear and non-linear analysis.
• Review results with responsible engineers and propose design improvements as necessary.
• Prepare reports of analysis findings.
• Perform additional projects as assigned.

Minimum Qualifications

• Bachelor's degree in mechanical engineering or related discipline.
• Minimum 10 years of experience in strength, stiffness, and fatigue CAE analysis for BIW and closures.
• Minimum 5 years of experience working with an automotive OEM.
• Experience using pre- and post-CAE modelling software Hyperworks.
• Experience using CAE analysis software Abaqus.
• Experience with FE-safe and nCode preferred but not required.
• Ability to manage own projects and mentor and assist junior CAE engineers.
• Skilled with Microsoft Office software including PowerPoint and Excel.
• Valid driver's license and satisfactory driving record.

The CAE Engineer shapes product development by identifying where finite element analysis can accelerate design decisions and proactively validating results against real-world data to drive model improvements. Embedded within the engineering community, the engineer generates high-level test reports and presents CAE conclusions to design and process teams, acting as a resource for less experienced colleagues.

Day-to-Day Responsibilities

• Work on difficult CAE problems to assist product development.
• Identify product design and development problems where CAE analysis can accelerate development.
• Proactively validate and correlate results with real-world data and make model improvements as deemed necessary.
• Develop a thorough understanding of business unit processes and hardware, and apply good knowledge of data analysis techniques to summarise CAE data.
• Generate high-level engineering test reports and present CAE results and conclusions to the design and process engineering community.

Knowledge Skills and Abilities

• Demonstrates conceptual and practical expertise in own discipline and basic knowledge of related disciplines.
• Has knowledge of best practices and how own area integrates with others, and is aware of the competition and differentiating factors in the market.
• Solves complex problems by taking a new perspective on existing solutions and exercising judgment based on the analysis of multiple sources of information.
• Impacts a range of customer, operational, project, or service activities within own team and other related teams, working within broad guidelines and policies.
• Explains difficult or sensitive information and works to build consensus.
• Acts as a resource for colleagues with less experience and may lead small projects with manageable risks and resource requirements.

Embedded within the manufacturing engineering team, the CAE Engineer creates, maintains, and governs machine programs, technical instructions, and tooling to deliver robust technical packages for all internally manufactured parts. Working closely with manufacturing engineering stakeholders, the engineer reviews method-of-manufacture changes and drives continuous improvement opportunities across operations while supporting the coaching and development of the CAE team.

Project Responsibilities

• Create, maintain, and govern machine programs, technical instructions, and machine tooling for existing and new components.
• Ensure the CAE team contribution delivers a robust technical package for all internally manufactured parts.
• Review and approve method of manufacture changes with manufacturing engineering stakeholders.
• Work with manufacturing engineering stakeholders to deliver programme and method of manufacture improvements encompassing technical continuous improvement opportunities with operations.
• Support the coaching and development of the CAE and operations team.

Technical Qualifications

• Proficient in machining processes including horizontal and vertical turning and multi-axis milling.
• Proficient in computer-aided machine software including Teamcenter, PLM, Siemens NX v7.5 or above, and Vericut v7.0 or above.
• Understanding and ability to use Mazatrol machine programming language and interface.
• Understanding of machine programming languages including Siemens 840D, Heidenhain, and Fanuc.
• Understanding of developing post processors.

Reporting to the engineering simulation lead, the CAE Engineer prepares and validates finite element models addressing geometrical and physical non-linearities such as elasticity, plasticity, and contact. Partnering with development, testing, customers, and suppliers, the engineer implements material property proposals and cost-reduction solutions that advance both technical outcomes and economic objectives.

Engineering Responsibilities

• Prepare finite element models with regard to geometrical and physical non-linearities such as elasticity, plasticity, and contact.
• Develop new FE methods according to internal or customer needs.
• Implement proposals concerning material properties, component optimisation, and cost reduction with regard to technical and economic aspects.
• Coordinate requirements together with the development and testing areas as well as customers and suppliers.
• Verify and validate FE models together with testing engineers.

Position Requirements

• Successfully finished university degree in mechanical, aeronautical, automotive engineering, or physics.
• At least 2 years of experience in the usage of numerical simulation methods (FE analysis) in the automotive industry and in the analysis of passenger car components.
• Practical application experience with simulation software including Abaqus or other non-linear solvers (MARC/MENTAT or ANSYS), Hypermesh, Hyperview, Simcenter 3D Durability, or Sigmasoft.
• Experience with programming languages such as Python or TCL/TK is preferable.
• Fluent in written and spoken English, German is preferable.
• Willingness to travel abroad.
• Analytical understanding and attention to detail.

The CAE Engineer leads preprocessing, meshing, and multi-domain linear and non-linear analysis using tools including Abaqus, LS-Dyna, Nastran, Optistruct, and StarCCM+, delivering correlated results and countermeasures that support frame, suspension, and body programs. Communicating across internal groups and travelling to client sites as required, the engineer advances design quality by optimising analyses against real-world test outcomes.

Scope of Work

• Utilise Hypermesh and ANSA for preprocessing tasks and meshing.
• Perform dynamic and static, linear and non-linear analysis utilising CAE tools such as Abaqus, LS-Dyna, Nastran, Optistruct, and StarCCM+.
• Interpret data, develop and report countermeasures using Hyperworks for post-processing.
• Optimise and correlate analyses with real-world test results.
• Communicate effectively within the group about issues and outside the group to accomplish goals.
• Analyse and resolve problems with moderate level of guidance and direction.
• Utilise Excel to create and update project schedules.
• Travel to client site as required.

Requirements

• Bachelor's degree in engineering and 2 to 7 years of relevant experience, or Master's degree in engineering and 1 or more years of relevant experience.
• Experience in frame, suspension, and body analysis.
• Expertise using Nastran for static and dynamic simulations.
• Expertise using Abaqus for non-linear analysis including geometry, material, and contact.
• Proficiency using Femfat, ANSA, Meta Post, HyperMesh, and HyperView.
• Experience developing CAE methods for strength-related evaluations is preferred.
• Proficiency using multi-body dynamics software is preferred.
• Good communication skills.

As the CAE Engineer, this role executes end-user support and subject matter expertise for PTC Creo and 3D routed systems including harness, cabling, and pneumatics across the product development environment. The engineering team relies on this work to maintain a well-governed interface between electrical and mechanical tools and to produce accurate user and admin documentation that supports model-based definition processes.

Key Deliverables

• Provide end-user support for PTC Creo.
• Serve as subject matter expert in model-based definition (MBD) and develop technical processes and procedures for MBD.
• Manage the interface between electrical and mechanical tools for routed systems.
• Serve as subject matter expert in 3D routed systems including harness, cabling, and pneumatics.
• Generate user and admin documentation.

Experience and Qualifications

• 5 or more years of related experience.
• Degree in engineering or a related technical field.
• Expert in PTC Creo usage and data management.
• Understanding of MBD concepts and application.
• Understanding of PDM systems including Teamcenter, EDM, and DS-E3 is preferred.
• Experience with other mechanical CAD tools and data management operations is preferred.
• Knowledge of eCAD tools such as Zuken E3.Series and Cadence OrCAD/Allegro is preferred.
• Experience working with service desk systems such as ServiceNow is preferred.

CAE Engineer refines structural and thermal analysis workflows for exhaust system components by conducting stress, modal, frequency response, fatigue life, and thermal management simulations that deliver autonomous recommendations to global program teams. Success in the position means standardised calculation methodologies, on-time quality metrics, and new FEA and thermal workflows that expand the organisation's in-house simulation capability.

Performance Expectations

• Analyse design concepts for structural and thermal specification as per customer specification or measurement data for design validation.
• Provide autonomous recommendations based on FEA and thermal results to the program team.
• Perform structural and dynamic simulations including stress analysis, modal analysis, frequency response analysis, and fatigue life predictions, as well as thermal management simulations such as heat transfer and thermal fatigue.
• Prepare technical reports and present to global stakeholders.
• Support and participate in internal and external professional networks including documentation.
• Identify and share lessons learned and best practices.
• Support internal CAE team-level trainings.
• Maintain and track quality and on-time delivery metrics for all work requests.
• Review quality of simulations executed by FE analysts, GETs, and PGETs.
• Support standardisation, harmonisation, and documentation of calculation methodologies and working procedures.
• Support development and introduction of new calculation methods and workflows in the field of FEA and thermal analysis.

Qualifications and Experience

• At least 3 years of experience in finite element analysis using Abaqus, Taitherm, and HyperWorks.
• 3 or more years of experience in providing design concepts, developing methodologies, standards, and writing procedures.
• Experience in simulation and methodological layout of exhaust system components considering dynamic and durability requirements.
• Theoretical knowledge of FEA, vibration, materials, and strength of materials.
• Knowledge of fatigue failure theory including LCF and HCF, and failure theories and their influence on durability failures.
• Mandatory proficiency in FEA and durability software including Abaqus, Optistruct, and Taitherm.
• Mandatory proficiency in FEA pre- and post-processing tools including HyperWorks and Abaqus Viewer.
• Knowledge of manufacturing processes including bending, canning, muffler manufacturing, stamping, and welding.
• Basic skills in design and project management.
• Proficiency in MS Office and Unix/Linux applications.
• Knowledge of Linux script writing and programming languages such as Python or Java is a plus.
• Self-driven, team-oriented, and willing to travel domestically or overseas as needed.

The CAE Engineer builds and executes numerical simulations of advanced damper designs using finite element method, selecting correct calculation methodologies and running Abaqus-based models from setup through post-processing to deliver practical engineering conclusions that verify and optimise designs against strength and durability requirements. Serving as an individual contributor within the engineering team, the engineer maintains complete records, proposes design improvements, and applies DOE and statistical analysis techniques to support complex simulation development plans.

Job Functions

• Understand simulation scope, requirements, and acceptance criteria and choose the correct calculation methodology to properly simulate problem physics.
• Prepare FEA models according to simulation objectives.
• Run simulations, identify potential convergence issues, and apply correct actions.
• Perform post-processing by proper interpretation of FEA results for engineering decisions.
• Report simulation results with appropriate summaries and practical engineering conclusions, and propose potential design improvements.
• Maintain records of all activities and results.

Technical Qualifications

• Master's degree in mechanical engineering with FEA specialisation.
• Strong knowledge of solid mechanics theory and fundamentals of machinery design.
• Proficient knowledge of finite element method theory and practical applications in static non-linear implicit, dynamic explicit, and NVH physics.
• Proficient knowledge and practical usage of Abaqus solver.
• Knowledge of optimisation techniques and the ability to plan and execute FEA simulation plans for complex design development.
• Knowledge of statistical analysis tools and DOE techniques to effectively optimise design.
• Experience with HyperMesh, nCode, Tosca Structure, Isight, and HyperStudy is advantageous.
• Programming capability in Python is advantageous.