Crash Safety Structure CAE Analyst

Job Description

We are the movers of the world and the makers of the future. We get up every day, roll up our sleeves and build a better world — together. At Ford, we’re all a part of something bigger than ourselves. Are you ready to change the way the world moves?

Product Development uses design thinking & user experience methods to deliver breakthrough products and services that delight our customers. We bring innovative, exciting, and sustainable ideas to life. We have opportunities around the world for you to contribute to advancements in autonomy, electrification, smart mobility technologies, and more!

• Use simulation tools and LS‑Dyna to conduct finite element analysis to predict and optimize vehicle crash performance in Front, Side, Rear and Roof strength test modes – for ICE, HEV and, most importantly, full BEV programs.
• Analyze test data and provide insights and recommendations for further improvements in vehicle design.
• Conduct DFMEA/Robustness in safety analysis of structures to ensure that corporate requirements are consistently met throughout the vehicle design and manufacturing processes.

• Perform structural analysis to ensure full‑vehicle robustly meets all applicable safety regulations and public domain requirements in US (FMVSS, IIHS, NCAP) and World‑wide (EuroNCAP, ECE, CNCAP, CIASI, etc).
• Conduct component/full‑vehicle crash tests as required to validate CAE models for accurate analysis / predictions.
• Collaborate with Body, Chassis, and Powertrain / Battery engineers to choose appropriate materials that balance strength, weight, and cost for optimal crash performance.
• Assess the impact of new/advanced materials on crash worthiness and structural integrity.
• Continuous improvement of crash worthiness methodologies and processes to enhance overall vehicle safety.
• Communicate findings, recommendations, and updates to stakeholders within the organization.
• Use simulation tools and LS‑Dyna to conduct finite element analysis to predict and optimize vehicle crash performance in Front, Side, Rear and Roof strength test modes – for ICE, HEV and BEV programs.
• Analyze test data and provide insights and recommendations for further improvements in vehicle design.
• Conduct DFMEA/Robustness in safety analysis of structures to ensure that corporate requirements are consistently met throughout the vehicle design and manufacturing processes.
• Perform structural analysis to ensure full‑vehicle robustly meets all applicable safety regulations and public domain requirements in US (FMVSS, IIHS, NCAP) and World‑wide (EuroNCAP, ECE, CNCAP, CIASI, etc).
• Conduct component/ full‑vehicle crash tests as required to validate CAE models for accurate analysis/predictions.
• Collaborate with Body engineers to choose appropriate materials that balance strength, weight, and cost for optimal crash performance.
• Assess the impact of new/advanced materials on crash worthiness, structural integrity, and high voltage systems, including BEV traction batteries.
• Continuous improvement of crash worthiness methodologies and processes to enhance overall vehicle safety.

• A Bachelor’s degree in mechanical engineering, automotive engineering, structural engineering, or a related field required.
• Minimum 5 years of CAE experience in automotive safety with emphasis on structural crash worthiness and high voltage system integrity (Hybrid and BEV architectures).
• Minimum of experience in 1 program cycles in design, development, and validation of crash worthiness with emphasis on Body‑on‑Frame vehicles.

• A Master’s degree in mechanical engineering, automotive engineering, structural engineering, or a related field required.
• Proficient in ICE/HEV/BEV vehicle architectures and loadpath analysis required to meet crash worthiness requirements in Front, Side, Rear impact modes including Roof strength.
• Experience with crash test coordination, analysis of crash test data, and involvement in vehicle safety assessments is highly valued.
• Very proficient in Finite Element Analysis (LS‑Dyna) and simulation tools used in crash worthiness analysis.
• Strong understanding of vehicle steel, aluminum and…