Senior Engineer – Finite Element Analysis (FEA)

Your Job

We are seeking a skilled Senior Engineer - FEA with minimum 5 years of experience in finite element analysis and simulation-driven product development. The role requires strong hands-on experience in building, solving, and interpreting structural, thermal, and mechanical simulation models, with the ability to translate analysis results into practical design recommendations. The candidate will work closely with Design, Materials, testing, and Manufacturing teams to improve product performance, reliability, and robustness

Our Team

At Molex we're committed to improving people's lives and making the world a better place. Connected Mobility Solutions (CMS), a business unit of Molex LLC, develops innovative products and solutions around automotive in-vehicle networking, infotainment, and vehicle communications. We put our customer first, developing and investing in key technologies for connected vehicle applications, constantly striving to improve and grow both personally and professionally. Come join us in our journey.

What You Will Do

• Perform end-to-end finite element analysis, including geometry cleanup, meshing, model setup, solution, post-processing, and technical reporting.

• Conduct linear and nonlinear structural analyses, including static strength, stiffness, deformation, contact, plasticity, and large-displacement assessments.

• Perform modal, vibration (Sine, Shock & Random), buckling, fatigue, Explicit, and thermal or thermo-mechanical analyses (CTE) based on product and program requirements.

• Develop high-quality finite element models using appropriate element types, mesh strategies, material models, loads, constraints, and contact definitions.

• Use commercial CAE tools such as ANSYS, Abaqus, HyperMesh, OptiStruct, or equivalent platforms for analysis and model preparation.

• Correlate simulation results with physical test data, identify gaps, and refine models to improve prediction accuracy.

• Evaluate results against Engineering requirements, applicable standards, and material allowable, and provide clear design recommendations.

• Collaborate with Design Engineers to support concept selection, design optimization, material selection, and failure-risk reduction.

Who You Are (Basic Qualifications)

• Bachelor's or master's degree in mechanical engineering, Applied Mechanics, Aerospace Engineering, or a related field.

• 5 years of relevant experience in finite element analysis, with demonstrated hands-on responsibility for complete FEA workflows.

• Strong fundamentals in solid mechanics, strength of materials, dynamics, heat transfer, and numerical methods.

• Hands-on working knowledge of at least one major FEA solver and one pre- and post-processing tool, such as ANSYS, Abaqus, HyperMesh, or equivalent.

• Experience in meshing, contact modelling, boundary-condition definition, material modelling, convergence studies, and result interpretation.

• Experience with structural, nonlinear, fatigue, vibration, Drop Analysis, Explicit Analysis, Crimping, thermal analysis and correlation with Engineering tests.

• Strong analytical, problem-solving, documentation, and communication skills, with the ability to present technical findings to cross-functional teams.

What Will Put You Ahead

• Experience in simulation of automotive or electromechanical products, including connectors, housings, terminals, or plastic and metal components.

• Knowledge of engineering plastics, metals, hyper-elastic materials, creep, plasticity, and temperature-dependent material behaviour.

• Exposure to optimization, design of experiments, sensitivity studies, or automation of repetitive CAE tasks using Python or scripting.

• Familiarity with CAD and PLM systems such as NX, Creo, Teamcenter, or equivalent tools.

• Experience working within APQP, DFMEA, DVP&R, or Stage-Gate product development processes.

At Koch companies, we are entrepreneurs. This means we openly challenge the status quo, find new ways to create value and get rewarded for our individual contributions. Any compensation range provided for a role is an estimate determined by available market data. The actual amount may be higher or lower than the range provided considering each candidate's knowledge, skills, abilities, and geographic location. If you have questions, please speak to your recruiter about the flexibility and detail of our compensation philosophy.

Who We Are

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At Koch, employees are empowered to do what they do best to make life better. Learn how our business philosophy helps employees unleash their potential while creating value for themselves and the company.

Additionally, everyone has individual work and personal needs. We seek to enable the best work environment that helps you and the business work together to produce superior results.