CAE Full-Vehicle Crash Engineer

Position Summary We are seeking a highly skilled CAE Crash Analyst to lead full-vehicle finite element simulations for structural integrity and occupant safety. The ideal candidate will bridge the gap between virtual engineering and physical testing, driving the development of vehicles that meet or exceed global regulatory and consumer protection standards (FMVSS, ECE, IIHS, C-NCAP).

Key Responsibilities

Full Vehicle Simulation: Develop, execute, and analyze non-linear transient dynamic finite element models for frontal, side, rear, and rollover crash scenarios.

Model Build & Debug: Manage the assembly of full-vehicle FE models (including subsystems like suspension and powertrain) and troubleshoot issues related to contact, material properties, and hourglassing.

Optimization: Collaborate with design teams to perform sensitivity studies and DOE (Design of Experiments) to optimize structural load paths and mass efficiency.

Correlation: Compare simulation results (force-deflection, accelerations, intrusion) against physical sled and vehicle-level test data to improve model fidelity.

Reporting: Translate complex simulation outputs (energy absorption, intrusion, dummy injuries) into clear, actionable engineering recommendations.

Innovation: Investigate and implement new material models (composites, high-strength steels, aluminum) and validate their behavior under dynamic loading.

Required Qualifications

Education: B.S. or M.S. in Mechanical, Aerospace, or Automotive Engineering (or related field).

Experience: 4+ years of experience specifically in full-vehicle crash analysis.

Technical Skills:

Software Proficiency: Expert-level command of LS-DYNA (Mandatory). Experience with ANSA or HyperMesh for pre-processing, and MetaPost or HyperView for post-processing.

Core Fundamentals: Strong grasp of FEA theory, plasticity, contact algorithms, and explicit time integration.

Regulatory Knowledge: Familiarity with FMVSS 208/214/216, ECE R94/R95, or IIHS protocols.

Soft Skills: Excellent problem-solving abilities, strong communication skills (technical writing and presentations), and the ability to collaborate effectively across global design teams.

Preferred Qualifications

• Experience with automated occupant positioning or safety system integration (airbags/seatbelts).

• Knowledge of mesh-free methods or multi-domain simulation (CFD/FEA coupling).

• Scripting proficiency (Python, Tcl/Tk, or MATLAB) to automate repetitive analysis tasks.