CAE Engineer
We are seeking a Freelance CAE Engineer to support the design and development of cutting-edge vehicle programs through advanced simulation and analysis. You will be responsible for planning, executing, and interpreting finite element analyses to guide key design decisions, improve performance, and ensure structural, durability, and safety targets are achieved across multiple systems.
Key Responsibilities:
- Create, refine, and validate finite element models for vehicle structures and components, including body, chassis, closures, and sub-systems.
- Perform linear and nonlinear static, dynamic, crash, and thermal analyses to support concept selection, detailed design, and validation.
- Collaborate with cross-functional engineering teams to influence architecture, materials, joining methods, and packaging using CAE insights.
- Execute design trade-off and optimization studies to balance mass, cost, manufacturability, and performance requirements.
- Correlate CAE predictions with test data, updating models, material cards, and boundary conditions to improve accuracy and robustness.
- Translate complex simulation outputs into concise engineering recommendations, highlighting risks, sensitivities, and alternative design paths.
- Prepare analysis plans, documentation of modeling assumptions, summary reports, and sign-off justifications in support of program milestones.
- Contribute to the development and standardization of CAE workflows, templates, and best practices for repeatable, high-quality simulations.
- Support physical test planning by defining critical load cases, instrumentation locations, and expected responses based on CAE results.
- Develop and implement automation, scripting, and data management solutions to streamline CAE processes and reduce dependence on physical testing.
Required Skills & Experience:
- 5–7 years of hands-on CAE/FEA experience in automotive, aerospace, or similar high-performance product development environments.
- Proficiency with industry-standard simulation tools (e.g., Abaqus, OptiStruct, Nastran, LS-DYNA, HyperMesh or comparable solvers and pre-/post-processors).
- Strong foundation in structural mechanics, fatigue, contact, nonlinear materials, crash dynamics, and vibration behavior of complex assemblies.
- Demonstrated ability to build efficient, high-quality FE models, including meshing strategy, joint modeling, realistic boundary conditions, and load definitions.
- Experience in model correlation, including comparison with test results, sensitivity studies, and iterative model refinement.
- Proven record of influencing design decisions using CAE, working within aggressive timelines and evolving requirements.
- Understanding of manufacturing processes (e.g., casting, stamping, extrusion, forming, welding, composites) and their impact on structural performance and durability.
- Strong written and verbal communication skills, with the ability to present technical conclusions to both engineering and non-technical stakeholders.
- Demonstrated analytical and problem-solving skills, including troubleshooting model setup, numerical stability, and convergence issues.
- Experience working with 3D CAD, engineering drawings, and GD&T, and converting design intent into accurate simulation models.
Education:
- Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or a closely related field.
Employment Type: Freelance
