Senior CAE Engineer - Structural Analysis & Optimization

Job Summary

Zenvo is a Danish hypercar manufacturer building some of the most extreme road cars in the world, in very limited numbers and with an uncompromising focus on performance, engineering and driver emotion.

As a small, fast-moving team, every engineer here has a direct impact on the finished car.

The Role

We're looking for a Senior CAE Engineer - Structural Analysis & Optimization to support the development of lightweight, high-performance vehicle structures across our vehicle programs. At Zenvo, balancing extreme performance, low mass, durability and vehicle refinement requires advanced simulation methods and deep engineering insight from the earliest concept phases through validation and homologation.

Working closely with Design, Vehicle Engineering, Safety Engineering, Program Management and Manufacturing, you will be responsible for delivering structural analysis and optimization activities across the vehicle. This includes carbon-fibre composite structures, aluminium and titanium components, suspension systems, subframes and other critical load-carrying assemblies.

You will play a key role in enabling innovative engineering solutions through advanced finite element analysis, helping shape vehicle architecture, structural performance and engineering decisions throughout the development process.

In addition to structural development, you will support vehicle attribute development through stiffness, vibration and NVH-related assessments, contributing to overall vehicle performance and quality.

This is a hands-on technical role requiring extensive experience in automotive CAE, lightweight design, structural optimization and composite engineering, with a strong understanding of both metallic and composite vehicle structures.

Key Responsibilities

• Perform structural CAE assessments for vehicle, subsystem and component development from concept through production.
• Develop and maintain high-quality finite element models for stiffness, strength, durability, fatigue and vibration assessments.
• Lead structural development of carbon-fibre composite, aluminium, titanium and mixed-material vehicle structures.
• Support the design and optimization of suspension systems, subframes, chassis structures and vehicle load paths.
• Conduct static, dynamic and non-linear structural analyses to support engineering decision-making throughout vehicle development.
• Drive optimization activities to achieve ambitious targets for mass, stiffness, durability and performance.
• Develop and evaluate composite laminates, bonded joints and hybrid material concepts.
• Work closely with Design and Engineering teams to improve structural efficiency while maintaining manufacturing feasibility and serviceability.
• Support vehicle-level stiffness, modal and vibration development, contributing to overall vehicle attribute performance and refinement.
• Correlate simulation results with test data and drive continuous improvement of modelling methodologies.
• Establish and improve CAE standards, processes and best practices across structural analysis and optimization activities.
• Collaborate with suppliers and engineering partners to assess and validate component and system performance.
• Clearly communicate technical findings, risks and recommendations to engineering teams and management.

Qualifications

• Minimum 5 years of automotive CAE experience within structural analysis, optimization or vehicle development.
• Proven experience delivering structural development programs from concept through validation and production release.
• Advanced proficiency with industry-standard CAE tools for structural simulation, optimization and post-processing.
• Strong experience with finite element modelling, structural analysis and optimization of vehicle systems and components.
• Demonstrated experience developing lightweight carbon-fibre composite and mixed-material vehicle structures.
• Extensive experience working with aluminium, titanium and composite load-carrying structures, including suspension systems, subframes and chassis components.
• Strong understanding of stiffness, strength, durability, fatigue and vibration analysis methodologies.
• Experience applying topology, shape, size and composite laminate optimization techniques to achieve demanding performance and mass targets.
• Experience correlating CAE results with physical testing and validation activities.
• Good understanding of vehicle attribute development, including structural dynamics, vibration behaviour and NVH fundamentals.
• Degree in Mechanical Engineering, Aerospace Engineering or a related technical field.
• Fluent English.
• Willingness to travel to test facilities and engineering partners.

Application Process:

Zenvo is an equal opportunity employer committed to diversity and inclusion in the workplace.