CAE Battery Model Build Engineer

Role Objective:

Deploy one (1) engineer to provide full vehicle CAE model build and ongoing support for battery pack CAE models across Structural Safety, Durability, and NVH domains. The engineer will build, update, debug, and deliver analysis-ready battery pack models integrated to the vehicle BIW, in accordance with Purchaser-provided standards for numbering, mesh criteria, and joining methodology.

Key Responsibilities/Scope of Services

• Develop and maintain battery pack CAE models for each major build release including:
• Durability models in Abaqus or OptiStruct template (per Purchaser requirement)
• LS-DYNA durability sub-models for the battery system (e.g., GroundStrike, TopStrike)
• NVH structural battery models in OptiStruct, including full pack content and BIW integration
• Structural Safety LS-DYNA crash models (homogenized sub-assemblies and/or higher fidelity per program phase)

Build full battery model content as required (structure, plastics, HV network, adhesives, potting) and connect to BIW using subsystem include files and master connection files (including BIW-to-subsystem connection files). Ensure subsystems are massed per BOM; represent non-modeled content using NSM cards/mass elements and manage trimmed mass and CoG targets as required. Implement joining representations per Purchaser standards (weld/bond/bolt); represent major bolted joints with solid bolt models and preload where required.

Deliver 0ms LS-DYNA model debugged to pass error-free model checks; include required instrumentation (force X-sections on major load paths, accelerometers at specified locations). Support high-fidelity explicit pack models as requested (e.g., cells, cooling plates/features, busbars, vents) and provide e-contented variants when required.

Delivery & Reporting Requirements

• Deliver models in compliance with the Purchaser Model Checklist and provide a Seller delivery checklist confirming model run-readiness and documenting any deviations.
• Report with each full vehicle CAE model delivery: global energy, mass scaling, and total model mass (as applicable to the domain).
• Maintain consistent mesh quality and alignment across domains where required.