Structural Safety CAE Engineer

Key Responsibilities:

Crashworthiness Simulation:

Perform full-vehicle and sub-system crash simulations (e.g., frontal, side, rear, rollover) using explicit analysis tools such as LS-DYNA, or Pam-Crash.

Analyze vehicle body structure deformation, energy absorption, and intrusion metrics to evaluate performance against regulatory and NCAP requirements.

Simulate and assess passive safety system integration (e.g., airbags, seatbelts, restraints) and occupant injury criteria (HIC, chest deflection, femur load).

Model Development & Validation:

Develop, assemble, and manage high-fidelity finite element (FE) models for body-in-white (BIW), closures, IP subsystems, and seating systems.

Correlate simulation results with physical crash test data; apply mesh refinement, material model tuning, and test-simulation alignment techniques.

Support the development of vehicle safety attributes early in the design phase through advanced CAE studies and design iteration.

Design Feedback & Optimization:

Provide design recommendations to improve crash performance, weight, cost, and manufacturability.

Use optimization tools (e.g., LS-OPT, HEEDS, mode FRONTIER) to drive trade-off studies and architecture refinement.

Conduct root-cause analysis for deviations in crash performance and provide actionable countermeasures.

Cross-Functional Collaboration:

Interface with vehicle architecture, body, interior, and restraint system teams to ensure integrated crash and safety performance.

Participate in safety attribute target setting, design reviews, DFMEA, and regulatory assessments (e.g., FMVSS, ECE R94/R95, GTR, GB).

Mentor junior CAE engineers and support knowledge sharing on tools, best practices, and process improvements.

Required Qualifications:

Bachelor's or master's degree in mechanical engineering, Automotive Engineering, or related discipline.

5–8+ years of experience in automotive crash CAE analysis and structural safety simulation.

Strong expertise in LS-DYNA, ANSA, Primer, and crash post-processing tools such as META, HyperView, or Animator.

Deep understanding of automotive safety regulations (FMVSS, Euro NCAP, China NCAP, etc.) and associated performance targets.

Hands-on experience with material modeling, contact definitions, airbag/seatbelt modeling, and dummy interactions (Hybrid III, THOR, etc.).

Preferred Qualifications:

Experience in BIW structure optimization for crash and lightweighting targets.

Knowledge of occupant restraint system integration and active safety interfaces.

Familiarity with scripting languages (Python, Tcl, etc.) for process automation.

Exposure to electric vehicle (EV) crash simulations including battery safety and structural intrusion.