CAE Engineer

HV Battery Structural CAE Engineer

V2

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Position

Description:

Job Title:

HV Battery Structural CAE Engineer

We are looking for an experienced structural CAE engineer to lead high-voltage battery internals and related system structural design using CAE tools. You will work with battery design and release engineers on cutting-edge battery technologies to ensure the battery functional environment operates within specified conditions. As a collaborative team player, you will create impact by working across the Electrified Powertrain Engineering organization and with key stakeholders of the battery business.

Skills Required:

CAE

Experience

Required:

• 4+ years of experience working with structural components and designs in an engineering environment.
• Bachelor's degree in Mechanical or Structural Engineering.

Experience Preferred:

• 5 or more years of experience specifically in CAE structural modeling and simulation analysis techniques using ABAQUS or equivalent, including experience selecting appropriate solution procedures for complex non-linear problems.
• M.S. in Mechanical Engineering or equivalent degree.
• Working knowledge of ABAQUS, Opti Struct Non-Linear, Hyper Mesh, Hyper View, ABAQUS Viewer, Teamcenter, 3

DEXPERIENCE (3DX), or equivalent tools (ANSYS, etc.).
• Working knowledge of CAE tools for fatigue assessments such as FEMFAT, nCode, fe-safe, or equivalent.
• Strong experience in correlating complex non-linear CAE models with physical test data, including sensitivity analysis and model tuning for improved accuracy.
• Extensive knowledge of various structural materials, high-strength material behavior, energy flow theory and analysis methods, fracture mechanics, and crack initiation/propagation.
• Working knowledge and experience using CAE pre-processing tools such as Hyper Mesh or equivalent for geometry cleanup and meshing, and ABAQUS, Nastran, or equivalent for CAE model solving and post-processing.
• Proficiency in ABAQUS scripting (Python) for model automation and advanced post-processing.
• Familiarity with sheet metal design specifications, sealing design, structural testing setup, and data collection.
• Familiarity with thermal-mechanical coupled analysis that considers temperature-dependent material properties, thermal expansion, and effects on structural integrity.
• Proven record of innovative applications and ability to introduce new ideas for product development.
• Working knowledge of optimization CAE tools such as mode FRONTIER, iSight, HEEDS, Tosca, or Opti Struct.
• Experience in physical testing is a plus.
• Ability to mentor junior engineers and collaborate effectively as a team player.
• Strong verbal and written communication and interpersonal skills.
• Experience with variability, robustness, and Six Sigma methodologies.

Education Required:

Bachelor's Degree

Additional Information:

*** POSITION IS HYBRID / (4 days per week in the office / Monday to Thursday)**
* • Build 3D battery internal structural analysis CAE models from CAD designs.
• Debug complex finite element (FE) models independently.
• Perform 3D structural simulations on high-voltage battery packs at the system, subsystem, and component levels to support internal design development, utilizing non-linear FEA codes such as ABAQUS, ANSYS, or Opti Struct Non-Linear, including pre- and post-processing with Hyper Mesh, Hyper View, and ABAQUS Viewer.
• Evaluate 3D structural analysis results and provide technical feedback and design direction to vehicle program and battery pack design teams.
• Collaborate with vehicle-level teams to obtain boundary conditions for battery pack structural-level simulations.
• Partner with battery lab and vehicle-level testing teams; specify instrumentation for data collection; process physical structural test results and use the data to correlate CAE models.
• Coordinate with extended overseas CAE teams for meshing and geometric cleanup tasks.
• Compile professional, organized, and structured reports detailing completed CAE work, including recommendations and conclusions.