Structural CAE Engineer – High Voltage Battery

Structural CAE Engineer – High Voltage Battery

We are seeking an experienced HV Battery Structural CAE Engineer to support the structural design and analysis of high-voltage battery systems and components using advanced CAE tools. This role partners closely with battery design and release engineering teams to evaluate structural performance, validate designs, and ensure battery systems operate within specified functional requirements. The position requires strong expertise in structural simulation, finite element analysis, and CAE model correlation with physical testing data.

KEY RESPONSIBILITIES

• 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 using non-linear FEA tools.
• Conduct pre-processing, meshing, simulation, and post-processing activities using applicable CAE software.
• Evaluate structural analysis results and provide technical recommendations and design guidance to engineering teams.
• Collaborate with cross-functional teams to obtain boundary conditions required for structural simulations.
• Partner with testing teams to define instrumentation requirements, process structural test results, and correlate CAE models with physical data.
• Coordinate CAE modeling activities, including meshing and geometry cleanup support.
• Prepare organized technical reports that summarize analysis results, recommendations, and conclusions.

REQUIRED QUALIFICATIONS

• Bachelor's degree in Mechanical Engineering, Structural Engineering, or a related field.
• 4+ years of experience working with structural components and designs in an engineering environment.
• Strong expertise in ABAQUS, HyperMesh, nCode or fe-safe, and 3DEXPERIENCE (3DX).
• Experience in CAE structural modeling and simulation analysis techniques using ABAQUS or equivalent software.
• Ability to select appropriate solution procedures for complex non-linear structural problems.
• Working knowledge of non-linear structural analysis tools such as ABAQUS, ANSYS, OptiStruct Non-Linear, or equivalent.
• Experience with CAE pre-processing, meshing, solving, and post-processing activities.
• Experience correlating CAE models with physical test data, including sensitivity analysis and model tuning.
• Knowledge of structural materials, material behavior, fracture mechanics, crack initiation, and crack propagation.
• Familiarity with fatigue assessment tools such as FEMFAT, nCode, fe-safe, or equivalent.
• Proficiency with HyperMesh, HyperView, ABAQUS Viewer, Teamcenter, and related CAE tools.
• Experience with ABAQUS scripting (Python) for automation and advanced post-processing.
• Familiarity with sheet metal design specifications, sealing design, structural testing setup, and data collection methods.
• Understanding of thermal-mechanical coupled analysis and temperature-dependent material behavior.
• Experience with CAE optimization tools such as modeFRONTIER, iSight, HEEDS, Tosca, or OptiStruct.
• Strong verbal and written communication skills.
• Ability to work effectively in a collaborative team environment.

PREFERRED QUALIFICATIONS

• Master's degree in Mechanical Engineering or a related field.
• 5+ years of experience in CAE structural modeling and simulation analysis.
• Experience in physical testing.
• Demonstrated record of innovation and application of new ideas in product development.
• Experience with variability, robustness, and Six Sigma methodologies.
• Experience mentoring junior engineers.

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