AI / Simulation Engineer (Structural/Finite Element Analysis)

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))
• Seismic Simulations
• 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

• Bachelors or Masters degree in Mechanical or Aerospace Engineering
• 3- 8 years of relevant experience in mechanical simulation, structural analysis, or CAE

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

• 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