Simulation Engineer, Finite Element Analysis

Job Responsibilities:

• Develop, execute, and review Finite Element Analysis (FEA) simulations using commercial Computer-Aided Engineering (CAE) tools to evaluate structural performance

• Perform a range of analyses, including:

  • Linear and nonlinear static analysis
  • Dynamic analysis (Modal Analysis, Harmonic Analysis, Random Vibration Analysis, Impact/Drop Analysis)
  • Thermal and thermo-mechanical coupled simulations
  • Fatigue analysis (High Cycle Fatigue (HCF) / Low Cycle Fatigue (LCF))

• Build simulation models with appropriate material models, boundary conditions, contacts, and loading scenarios

• Apply knowledge of material behavior (metals, plastics, hyper elastic materials, and basic failure models) in simulations

• Evaluate simulation results to identify stress, deformation, fatigue life, and failure risks

• Perform hand calculations and engineering checks to validate FEA results using first principles

• Support Verification and Validation (V&V) efforts by correlating simulation outcomes with physical test data

• Assist in root-cause analysis and failure investigations using simulation results

• Prepare clear technical reports and documentation for internal stakeholders and customers

• Collaborate with design, test, and manufacturing teams to support simulation-driven design improvements

• Ensure simulation approaches align with industry standards and guidelines (e.g., American Society of Mechanical Engineers (ASME), International Organization for Standardization (ISO), American Society for Testing and Materials (ASTM))

• Contribute to continuous improvement of modeling practices, templates, and workflows

Qualifications:

• Bachelor’s or Master’s degree in Mechanical or Aerospace Engineering
• 4-8 years of relevant experience in mechanical simulation, structural analysis, or CAE

Strong fundamentals in:

• Mechanics of materials
• Structural mechanics and dynamics
• Finite Element Method (FEM) theory

Hands-on experience with FEA software, such as:

• ANSYS Mechanical / Workbench
• Abaqus and/or LS-DYNA (explicit experience is a plus)
• Working knowledge of CAD tools such as SolidWorks or CATIA
• Understanding of meshing techniques, element selection, and convergence studies
• Ability to interpret complex simulation data and translate results into engineering insights
• Good communication skills and ability to document technical findings clearly
• Ability to work independently on assigned tasks while collaborating effectively within a team
• Experience with explicit dynamics (impact, drop, crash-type simulations)
• Exposure to HyperMesh or similar pre-processing tools
• Basic scripting or automation experience using Python or VB
• Familiarity with design optimization or DOE (Design of Experiment) techniques
• Exposure to physical testing and test–simulation correlation
• Understanding of failure criteria and damage modeling