Crash Safety Structure CAE Analyst

Ford • Dearborn, MI

1d • Hybrid

About The Position

We are the movers of the world and the makers of the future. We get up every day, roll up our sleeves and build a better world -- together. At Ford, we’re all a part of something bigger than ourselves. Are you ready to change the way the world moves?
Product Development uses design thinking & user experience methods to deliver breakthrough products and services that delight our customers. We bring innovative, exciting, and sustainable ideas to life. We have opportunities around the world for you to contribute to advancements in autonomy, electrification, smart mobility technologies, and more!
The skills required for an experienced Structural Crashworthiness Engineer encompass a blend of technical expertise, analytical capabilities, communication skills, and industry knowledge.
In this position...
Use simulation tools and LS-Dyna to conduct finite element analysis to predict and optimize vehicle crash performance in Front, Side, Rear and Roof strength test modes - for ICE, HEV and, most importantly, full BEV programs.
Analyze test data and provide insights and recommendations for further improvements in vehicle design.
Conduct DFMEA/Robustness in safety analysis of structures to ensure that corporate requirements are consistently met throughout the vehicle design and manufacturing processes.

Requirements

• A Bachelor’s degree in mechanical engineering, automotive engineering, structural engineering, or a related field required.
• Minimum 5+ years of CAE experience in automotive safety with emphasis on structural crashworthiness and high voltage system integrity (Hybrid and BEV architectures).
• Minimum of experience in 1 program cycles in design, development, and validation of crashworthiness with emphasis on Body-on-Frame vehicles.

Nice To Haves

• A Master’s degree in mechanical engineering, automotive engineering, structural engineering, or a related field required.
• Proficient in ICE/HEV/BEV vehicle architectures and loadpath analysis required to meet crashworthiness requirements in Front, Side, Rear impact modes including Roof strength.
• Experience with crash test coordination, analysis of crash test data, and involvement in vehicle safety assessments is highly valued.
• Very proficient in Finite Element Analysis (LS-Dyna) and simulation tools used in crashworthiness analysis.
• Strong understanding of vehicle steel, aluminum and plastic materials and the implications for crashworthiness.
• Thorough knowledge of safety regulations and standards, such as FMVSS (Federal Motor Vehicle Safety Standards) and public domain requirements such as NCAP, IIHS, etc.
• Strong analytical and problem-solving skills to identify safety risks, propose solutions, and contribute to continuous improvement.
• Understanding of quality control processes (Failure Mode Avoidance, DFMEA, Robustness) and a proactive approach to identifying areas for improvement in safety methodologies and processes.
• Strong background in vehicle design and engineering principles, with a focus on safety-related aspects.
• Effective communication skills, both written and verbal, to convey complex technical information.
• Ability to work collaboratively with cross-functional teams, including design, engineering, testing, and regulatory compliance teams.

Responsibilities

• Perform structural analysis to ensure full-vehicle robustly meets all applicable safety regulations and public domain requirements in US (FMVSS, IIHS, NCAP) and World-wide (EuroNCAP, ECE, CNCAP, CIASI, etc).
• Conduct component / full-vehicle crash tests as required to validate CAE models for accurate analysis / predictions.
• Collaborate with Body, Chassis, and Powertrain / Battery engineers to choose appropriate materials that balance strength, weight, and cost for optimal crash performance.
• Assess the impact of new/advanced materials on crashworthiness and structural integrity.
• Continuous improvement of crashworthiness methodologies and processes to enhance overall vehicle safety.
• Communicate findings, recommendations, and updates to stakeholders within the organization.
• Use simulation tools and LS-Dyna to conduct finite element analysis to predict and optimize vehicle crash performance in Front, Side, Rear and Roof strength test modes - for ICE, HEV and BEV programs.
• Analyze test data and provide insights and recommendations for further improvements in vehicle design.
• Conduct DFMEA/Robustness in safety analysis of structures to ensure that corporate requirements are consistently met throughout the vehicle design and manufacturing processes.
• Perform structural analysis to ensure full-vehicle robustly meets all applicable safety regulations and public domain requirements in US (FMVSS, IIHS, NCAP) and World-wide (EuroNCAP, ECE, CNCAP, CIASI, etc).
• Conduct component/ full-vehicle crash tests as required to validate CAE models for accurate analysis/predictions.
• Collaborate with Body engineers to choose appropriate materials that balance strength, weight, and cost for optimal crash performance.
• Assess the impact of new/advanced materials on crashworthiness, structural integrity, and high voltage systems, including BEV traction batteries.
• Continuous improvement of crashworthiness methodologies and processes to enhance overall vehicle safety.
• Communicate findings, recommendations, and updates to stakeholders within the organization.

Benefits

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up childcare and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Number of Employees: 5,001-10,000 employees