Structural CAE Engineer (ABAQUS & HyperMesh)

Job Title

Structural CAE Engineer (ABAQUS & HyperMesh)

Overview

We are seeking an experienced  Structural CAE Engineer to support the structural design and analysis of high-voltage battery systems using advanced CAE tools. The ideal candidate will collaborate with battery design teams to develop, analyze, and validate structural performance while supporting innovative battery technologies.

This is a hybrid position requiring 4 days per week onsite (Monday–Thursday).

Key Responsibilities

• Build 3D structural CAE models for battery internal components from CAD data.
• Develop and debug complex finite element models independently.
• Perform nonlinear structural simulations for battery packs at the system, subsystem, and component levels using CAE tools.
• Conduct pre-processing, meshing, simulation setup, post-processing, and result evaluation.
• Provide technical recommendations and design guidance based on simulation results.
• Collaborate with cross-functional engineering teams to obtain simulation boundary conditions.
• Support correlation of CAE models with physical testing data.
• Coordinate with CAE teams supporting meshing and geometry cleanup activities.
• Prepare clear, organized technical reports documenting analysis, conclusions, and recommendations.

Required Qualifications

• Master's degree in Mechanical Engineering (including FEA coursework).
• Graduate-level coursework in Finite Element Analysis (FEA).
• Thesis, research, or project experience involving structural analysis.
• Experience with nonlinear FEA projects.
• Minimum 4 years of experience working with structural components and designs in an engineering environment.
• Minimum 3 years of experience using ABAQUS for nonlinear finite element analysis (5+ years preferred).
• Strong expertise in:
  • ABAQUS
  • HyperMesh
  • nCode or fe-safe
  • 3DEXPERIENCE (3DX)
• Experience building and setting up finite element models.
• Experience evaluating simulation results and correlating CAE results with physical testing.
• Ability to independently modify and assess finite element meshes.
• Strong written and verbal communication skills.

Preferred Qualifications

• 5+ years of CAE structural modeling and nonlinear simulation experience.
• M.S. in Mechanical Engineering or equivalent.
• Experience with:
  • OptiStruct Non-Linear
  • HyperView
  • ABAQUS Viewer
  • Teamcenter
  • ANSYS or equivalent CAE tools
• Experience with fatigue analysis tools such as FEMFAT, nCode, or fe-safe.
• Knowledge of structural materials, fracture mechanics, crack propagation, and energy flow analysis.
• Experience with Python scripting in ABAQUS.
• Familiarity with thermal-mechanical coupled analysis.
• Experience using optimization tools such as modeFRONTIER, iSight, HEEDS, Tosca, or OptiStruct.
• Experience with physical testing and validation.
• Ability to mentor junior engineers and collaborate effectively within cross-functional teams.
• Knowledge of variability, robustness, and Six Sigma methodologies.

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