CAE Engineer

Stealth-mode Battery Startup•San Jose, CA

21h•Onsite

About The Position

We are seeking a CAE Mechanical Engineer to lead and execute high-fidelity structural simulations for lithium-ion battery systems across the cell, module, and pack levels. This role is integral to bridging design concepts into manufacturable, reliable hardware by modeling how complex electro-mechanical systems behave under real-world conditions. You will work closely with mechanical design, test, and manufacturing teams to inform design architecture through simulation-driven insights and best practices.

Requirements

B.S. or M.S. in Mechanical Engineering, Applied Mechanics, or related discipline.
5+ years of experience in mechanical FEA, ideally within battery systems or similar dense electro-mechanical assemblies.
Proven proficiency in FEA tools such as Abaqus, ANSYS, or LS-DYNA; deep understanding of crash, vibration, and non-linear analyses preferred.
Strong skills in model setup (meshing, contact definition, material property assignment, boundary condition management).
Demonstrated ability to correlate simulation to test data and validate model accuracy.
Excellent communicator—capable of presenting simulation results, limitations, and trade-offs to multidisciplinary teams.
Comfortable working in fast-paced, iterative environments with evolving product requirements.

Nice To Haves

Support the development of fatigue analysis methodologies, particularly for polymers or adhesive joints.
Lay the foundation for in-house battery crash and impact simulation capabilities: Model mechanical behavior of cells during impact. Collaborate with OEMs on vehicle-level integration and crash safety strategy.

Responsibilities

Perform mechanical FEA under diverse loading conditions including crush, vibration, drop, thermal expansion, swelling, crash and underbody impact.
Build and refine detailed simulation models using CAD and empirical inputs, with rigorous attention to mesh quality, materials, contacts, and boundary conditions.
Conduct simulations using Abaqus, ANSYS, LS-DYNA, or similar tools; analyze results to assess deformation, failure risk, and design sensitivity.
Correlate simulation outputs with physical test data (e.g., strain gauges, displacements, fracture behavior) to validate and improve model fidelity.
Rapidly iterate on design alternatives and provide clear, actionable simulation feedback to design teams.
Own analysis workflows for: First Mode and Modal Analysis, Shock and Vibration Evaluation, Underbody Impact Scenarios, Side Pole Impact.
Contribute to the selection and integration of solver tools, pre/post-processors, and overall CAE infrastructure.
Define, document, and continuously improve best practices and workflows to ensure robust, repeatable analysis pipelines.
Develop and validate material models for CAE use—ideally by designing and executing custom test programs to generate material cards.
Support the development of fatigue analysis methodologies, particularly for polymers or adhesive joints.
Lay the foundation for in-house battery crash and impact simulation capabilities: Model mechanical behavior of cells during impact. Collaborate with OEMs on vehicle-level integration and crash safety strategy.
Partner with Product Development on mechanical hardware, especially: Underbody protective elements, Structural enclosures, Pack framing and load-bearing components.
Contribute to the design and optimization of next-generation battery compression systems, including advanced “quilted” or pre-formed plate concepts.