AI / Simulation Engineer, Finite Element Analysis

In this role, you will develop and refine robust finite element models, perform simulations under diverse loading conditions, and correlate analytical results with physical testing to ensure designs meet safety, reliability, and regulatory standards.

You will collaborate closely with cross-functional teams—including design, testing, and manufacturing—to drive simulation-led design decisions and support customer and compliance requirements. This position is well-suited for an engineer with strong fundamentals in mechanics of materials, hands-on FEA expertise, and the ability to interpret complex results and communicate clear, actionable engineering insights.

Job 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))

• 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

Qualifications:

• Bachelor’s or Master’s degree in Mechanical or Aerospace Engineering 
• 4-8 years of relevant experience in mechanical simulation, structural analysis, or CAE 

Strong fundamentals in:

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

Hands-on experience with FEA software, such as:  

• 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