Product Design Engineer
This CAE Engineer position within the Underbody Systems team is a critical role dedicated to the structural simulation of advanced suspension architectures and steering components. The position centers on translating real-world physical phenomena into highly accurate CAE models, playing an active part in shaping the structural integrity and performance of future vehicles. This role utilizes advanced FEA methods to provide fundamental engineering understanding, optimize structural designs, and make recommendations that ensure suspension architectures and steering systems are robust, manufacturable, and cost-effective while meeting strict internal quality and customer requirements.
Perform system-level strength and fatigue assessments (Linear and Non-Linear) for full-system suspension architectures and components, including the structural evaluation of rubber materials for bushings or damper seals.
Assist in conducting comprehensive structural analyses on a wide variety of steering components and full-system assemblies.
Provide program design alternatives by running large Design of Experiments (DOE) CAE studies. Optimize the structural performance, mass, and cost of complex systems using advanced topology, gauge, and shape optimization tools.
Apply scripting languages (like Python or TCL) to automate repetitive CAE pre/post-processing tasks. Support the continuous improvement and development of new CAE engineering standards and methods.
Lead or support cross-functional issue resolution by partnering with Design & Release (D&R) Engineers across different functions to evaluate architecture proposals and ensure compliance with vehicle requirements.
Create accurate CAE engineering status reports, verify completeness of structural assessments, and develop presentations for technical management and leadership.
Demonstrated ability to provide technical direction, mentor support staff, and manage large-scale analyses independently.
Bachelor of Science (B.S.) in Mechanical Engineering, Automotive Engineering, Aerospace Engineering, or a related field.
Master of Science (M.S.) in Mechanical Engineering or related field is preferred.
2 to 5+ years of automotive product development experience, specifically focused on Durability and structural analysis of suspension architectures or steering components (for experienced candidates).
Foundational knowledge of Finite Element Analysis (FEA), solid mechanics, and fatigue principles, including experience with solvers like Abaqus and OptiStruct (or equivalent).
Hands-on experience with industry-standard FEA solvers, specifically Abaqus/Standard or OptiStruct.
Familiarity with CAE pre- and post-processing and meshing tools (e.g., HyperWorks, ANSA, SimLab, or equivalent).
Knowledge of non-linear material modeling, such as hyperelastic rubber materials used in suspension bushings or damper seals (for experienced candidates).
Experience with fatigue life evaluation software (e.g., nCode DesignLife, FEMFAT, or fe-safe).
Experience with Optimization and DOE tools (e.g., OptiStruct, Tosca Structure, ModeFRONTIER, HEEDS).
Proficiently uses CATIA V5/V6 and similar CAD software (e.g., 3DX, NX, SolidWorks), along with Teamcenter and Vismockup, to efficiently create and manage robust, parametric, and associative Build to Print (B2P) parts.
Develop high-quality 3D CAD design concepts and alternatives promptly.
Creates and manages assemblies, drawings, motion files, and other related CAD data, as well as the complete vehicle environment with all system interfaces.
Strong analytical, problem-solving, and communication skills to effectively translate analysis data into actionable design recommendations.