CAE Engineer General

Job Title: CAE Engineer
Location: Dearborn, MI
Job Type: W2 Contract
Expected hours per week: 40 hours per week
Schedule: 7:00am - 4:00pm EST
Pay: $40-$42 per hour

Job Summary

Experienced HV Battery Structural CAE Engineer responsible for leading structural design and analysis of high-voltage battery internals using advanced CAE tools. Works cross-functionally with battery design, release, and vehicle teams to ensure structural integrity and performance within specified conditions, supporting development of next-generation electrified powertrain systems.

Responsibilities

• Build 3D battery internal structural CAE models from CAD designs
• Debug complex finite element (FE) models independently
• Perform 3D structural simulations at system, subsystem, and component levels using non-linear FEA tools (ABAQUS, ANSYS, OptiStruct)
• Conduct pre- and post-processing using tools such as HyperMesh, HyperView, and ABAQUS Viewer
• Analyze simulation results and provide technical feedback and design direction to engineering teams
• Collaborate with vehicle-level teams to define boundary conditions for simulations
• Partner with lab and testing teams to support instrumentation, data collection, and correlation of CAE models with physical test data
• Coordinate with global/overseas CAE teams for meshing and geometry cleanup
• Prepare structured reports summarizing analysis, findings, and recommendations

Education / Experience Required:

• Bachelor’s degree in Mechanical Engineering, Structural Engineering, or related field
• 4+ years of experience working with structural components and design in an engineering environment
• Strong expertise in CAE tools including ABAQUS, HyperMesh, nCode/fe-safe, and 3DEXPERIENCE (3DX)
• Experience with structural modeling, non-linear analysis, and simulation techniques

Preferred:

• 5+ years of experience in CAE structural modeling and simulation analysis
• Master’s degree in Mechanical Engineering or related field
• Working knowledge of tools such as OptiStruct Non-Linear, HyperView, Teamcenter, ANSYS, and optimization tools (modeFRONTIER, HEEDS, Tosca, iSight)
• Experience with fatigue analysis tools (FEMFAT, nCode, fe-safe)
• Strong experience correlating CAE models with physical test data, including sensitivity analysis and model tuning
• Knowledge of structural materials, fracture mechanics, and crack propagation
• Experience with Python scripting in ABAQUS for automation
• Familiarity with sheet metal design, sealing design, and thermal-mechanical coupled analysis
• Exposure to Six Sigma, robustness/variability methods, and physical testing
• Ability to mentor junior engineers and strong communication skills