{"id":3166283,"url":"https://alion.io/job/rebuild-manufacturing-principal-design-and-simulation-engineer","title":"Principal Design and Simulation Engineer","company":{"id":94284,"name":"Re:Build Manufacturing","domain":"rebuildmanufacturing.com","url":"https://alion.io/company/re-build-manufacturing","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Greenhouse","truth_index":{"grade":"B","score":77,"open_postings":31,"ghost_share":0,"stale_share":0.71,"repost_share":0,"time_to_fill_p50_days":70,"computed_at":"2026-10-28T05:59:10Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"lead","employment_type":null,"work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Rochester, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":120000,"max":151000,"currency":"USD","period":"year","gross":null,"usd_annual":151000},"salary_estimate":null,"experience_years_min":10,"visa_sponsorship":false,"relocation_package":false,"has_equity":true,"technologies":[{"name":"ANSYS","optional":false},{"name":"SolidWorks","optional":false},{"name":"AutoCAD","optional":true}],"status":"live","first_seen_at":"2026-10-23T15:18:14Z","employer_posted_date":"2026-10-23","last_verified_at":"2026-10-28T23:25:17Z","board_verified":true,"closed_at":null,"days_open":5,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":5},"description":"About Re:Build \nAt Re:Build, our mission is to ensure the next generation of important products are made, at scale, in America. We are laying the foundation for a better future for our customers, employees, and communities by revitalizing America's manufacturing base and creating meaningful jobs across the country, including in historically deindustrialized regions. \nWe operate an advanced, end-to-end manufacturing platform that partners with industrial companies and innovators to take products from first concept to full-scale production in critical verticals including aerospace and defense, electrification, medical, energy and environment, and robotics and automation. \nThe way we operate is as important as the work we do. It's guided by The Re:Build Way, 16 principles that shape how we collaborate with each other, partner with our customers and vendors, and contribute to the communities where we operate. (link to The Re:Build Way principles) \nAbout Re:Build Optimation\nAt Re:Build Optimation, we specialize in delivering custom-engineered process equipment and automated systems to clients across the globe. With nearly 40 years of experience in complex chemical process systems, we have built a reputation for precision, reliability, and innovation. Our multidisciplinary team of 70+ engineers, designers, and programmers, combined with 150,000 square feet of fabrication space and over 70 skilled tradespeople, allows us to provide full turnkey solutions-from initial concept through fabrication, installation, and commissioning.\nAs part of Re:Build Manufacturing, we leverage the strength of a national industrial powerhouse while maintaining the agility and personalized service of a niche firm. We serve industries ranging from traditional and green energy to chemicals, pharmaceuticals, food & beverage, glass, and advanced manufacturing, offering tailored solutions that optimize efficiency and performance.\nAt Re:Build Optimation, we believe in a collaborative approach, working closely with our clients to develop solutions that align with their unique operational goals. Our deep industry expertise and end-to-end capabilities make us the ideal partner for companies seeking cutting-edge automation, process control, and engineered systems.\nWho We Are Looking For\nRe:Build Optimation is seeking an experienced Principal Design and Simulation Engineer to serve as a technical expert in structural, thermal, and fluid simulation for industrial machinery and equipment. In this role, you'll apply your expertise in Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) to tackle complex engineering challenges, validate designs, and help deliver reliable, high-performing manufacturing solutions.\nYou'll work closely with mechanical design engineers, project teams, and customers to translate simulation results into practical design improvements. We're looking for someone who combines deep technical knowledge with strong problem-solving skills, enjoys mentoring others, and can confidently guide engineering decisions.\nThis opportunity is ideal for an experienced engineer who enjoys technical leadership, collaboration, and contributing to diverse industrial machine design projects from concept through commissioning.\nWho We Are Looking For\nRe:Build Optimation is seeking an experienced Principal Design and Simulation Engineer to lead structural, thermal, and fluid simulation efforts for industrial machinery and equipment. You'll use your expertise in Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) to solve engineering challenges, improve equipment performance, and support innovative manufacturing solutions.\nIn this role, you'll collaborate with mechanical design engineers, project teams, and customers to turn simulation results into practical design improvements. We're looking for a collaborative problem-solver who enjoys sharing knowledge, mentoring engineers, and helping teams make informed technical decisions.\nYou'll have the opportunity to contribute your expertise across a variety of industrial projects, from early design through commissioning, while helping strengthen our engineering capabilities.\nWhat You Get To Do\nLead structural, thermal, and fluid simulations (FEA/CFD) for industrial machinery and equipment projects.\nPerform and validate simulations using SolidWorks Simulation, SolidWorks Flow Simulation, Ansys, and Ansys Fluent.\nPartner with mechanical design engineers to define simulation requirements, boundary conditions, meshing strategies, and CAD model preparation.\nEvaluate mechanical systems, including structural weldments, piping, pressure vessels, rotating equipment, and automated machinery.\nTranslate simulation results into practical recommendations that improve equipment safety, reliability, and performance.\nDevelop simulation standards, validation methods, and best practices to improve analysis accuracy and consistency.\nReview and approve engineering calculations, simulation reports, and technical documentation.\nMentor engineers, share technical knowledge, and guide project teams in applying simulation insights to design decisions.\nCollaborate with customers and cross-functional teams to develop solutions, communicate findings, and support project execution.\nContribute to project estimates, proposals, technical reviews, field assessments, and commissioning activities.\nSupport compliance with applicable engineering codes, safety standards, and regulatory requirements.\nWhat You Bring To The Team\nBachelor's or master's degree in Mechanical Engineering or an equivalent engineering discipline.\n10-15 years of relevant experience in industrial machinery, manufacturing, or capital equipment engineering, including significant FEA/CFD experience.\nProficiency in SolidWorks, including Simulation/FEA and Flow Simulation, with experience using Ansys and Ansys Fluent.\nStrong understanding of simulation techniques, including meshing, boundary conditions, material properties, convergence, and validation.\nAbility to collaborate with mechanical design engineers to prepare simulation-ready CAD models and improve designs.\nKnowledge of mechanical engineering principles, fabrication methods, and industry codes such as ASME, API, and NFPA.\nExperience defining technical requirements, estimating engineering costs, and supporting project delivery.\nStrong communication, analytical, and problem-solving skills, with an interest in mentoring and developing others.\nCommitment to safe engineering practices and continuous improvement.\nAbility to work on-site in Rochester and/or Rush, NY, with travel as needed (typically less than 25%).\nPreferred Skills\nProfessional Engineer (PE) license.\nExperience with automated machinery, robotics, precision motion systems, web handling, piping, pressure vessels, or related mechanical systems.\nExperience validating simulation results through physical testing.\nKnowledge of fatigue analysis, vibration analysis, topology optimization, or thermal-fluid analysis.\nFamiliarity with advanced SolidWorks tools, AutoCAD, Creo/ProE, or similar software.\nExperience with ISO 9001, Lean, Six Sigma, or continuous improvement practices.\nCompensation \nThe base salary range for this position is $120,000 - $151,000 per year. This range represents the Company’s good faith estimate of the base compensation for this role at the time of posting. Actual compensation will be determined based on several factors, including but not limited to relevant experience, skills, qualifications, internal equity, and geographic location. In addition to base salary, this role may be eligible for annual incentive compensation and/or long-term incentives, subject to Company plans. The Company offers a comprehensive benefits package including medical, dental, vision, retirement, paid time off, and other benefits. \nThe BIG payoff\nWe are a company who is going to make a difference in the industries and the communities in which we choose to operate. Every employee of Re:Build will share ownership in the company and will share in the financial rewards of the success we achieve together, at all levels of the company!\nWe want to work with people that reflect the communities in which we operate\nRe:Build Manufacturing is proud to be an Equal Employment Opportunity and Affirmative Action employer. We do not discriminate based upon race, color, religion, gender, gender identity or expression, sexual orientation, national origin, genetics, disability, age, veteran status, marital status, parental status, cultural background, organizational level, work styles, tenure and life experiences. Or for any other reason.\nRe:Build is committed to providing reasonable accommodations for qualified individuals with disabilities in our job application procedures. 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