Senior CAE Analyst; Safety

At Roush, we fuse technology and engineering to provide product development solutions to customers in a diverse range of industries. Widely recognized for providing engineering, testing, prototype, and manufacturing services to the transportation industry, Roush also provides significant support to the aerospace, defense and theme park industries. With over 2,400 employees in facilities throughout the United States, Europe, Asia, and South America, our unique combination of creativity and tenacity activates big ideas on a global stage.

CAE Senior Analyst (Safety) – located in Livonia, MI. This role performs Finite Element Analysis (FEA) to solve Crash Structural Safety problems and supports the engineering team in the upfront design of automotive, aerospace, entertainment, and industrial segments.

• Build safety models for automotive, aerospace, and entertainment applications using commercial CAE tools such as LS‑Dyna, Radioss, Abaqus Explicit.
• Run safety and strength/durability simulations, postprocess results, and provide engineering solutions.
• Work independently on strength or durability attributes using solvers such as Abaqus or Nastran.
• Master new CAE tools quickly and keep abreast of new software capabilities.
• Collaborate with groups within the CAE department to enhance predictive accuracy and reduce development cycles.
• Establish and refine simulation methodologies to improve accuracy and shorten timelines.
• Execute projects independently, including direct communication with customers, to develop effective design solutions using CAE tools.
• Manage multiple projects simultaneously, ensuring timely and high‑quality deliverables.
• Develop innovative techniques or processes to advance the team.
• Provide technical support to marketing and sales teams to enhance customer engagement and business development efforts.

• Bachelor of Science in Mechanical or Aerospace Engineering with coursework in Finite Element Analysis, Strength of Materials, Mechanical behavior of metals.
• Experience in non‑linear explicit, complex full vehicle structural FEA modeling, analysis and correlation with test data.
• 3+ years of safety modeling experience building crash safety FEA models using tools such as ANSA, Hypermesh.
• Knowledge of mechanical systems and vehicle structure for various impact modes, safety protocols, and crash development principles.
• Good attention to detail and ability to use hand calculations and free‑body diagrams to validate input and results. Excellent verbal and written communication skills.
• Advanced software skills in finite element pre‑processors, solvers, and post‑processors (Altair Hyperworks, ANSA & META, LS‑Dyna).
• Strong verbal, written, and interpersonal communication skills and ability to train and mentor junior analysts.

• Master of Science or Ph.D. in Mechanical or Aerospace Engineering with coursework in Finite Element Analysis, Strength of Materials, Mechanical behavior of metals.
• Experience writing process automation using Python, Excel VBA, or C functions.
• U.S. citizenship allowing for International Traffic in Arms Regulations (ITAR) compliance.
• Experience working on occupant safety models and restraint system development.
• Proficiency in FEA/fatigue simulation software (Nastran, Abaqus, nCode).
• Experience with real‑world data integration and experimental validation.
• Strong understanding of safety protocols such as FMVSS, NCAP, IIHS, EuroNCAP, CFR Part 25.
• Proven ability to work independently and collaborate with cross‑functional teams, presenting technical findings to stakeholders.

Our full‑time benefits include medical, dental, vision, life insurance, earned sick time, short‑term and long‑term disability, 401(k), tuition reimbursement, employee referral bonus program, paid vacation, and paid holidays.

Roush is an EO employer – Veterans, Disabled and other protected categories. If you need a reasonable accommodation for our employment application process due to disability, please contact Roush Talent Acquisition at 734‑779‑7087.