Exterior Structures CAE Engineer

Ford • Dearborn, MI

2d • $74,300 - $166,200 • Hybrid

About The Position

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! We are seeking a talented and detail-oriented Automotive Structures CAE Engineer to join our engineering team. In this role, you will be responsible for performing finite element analysis (FEA) and structural optimization to support the design, development, and validation of Unibody and Body-on-Frame structures and components. You will work closely with design, test, and program engineering teams to deliver lightweight, durable, and safety-compliant structural solutions.

Requirements

• Bachelor’s degree in mechanical engineering, Automotive Engineering, or a related engineering discipline (required).
• 3 years of relevant industry experience in automotive or related structural CAE applications (adjust based on level: entry, mid, or senior).
• Familiarity with design of experiments (DOE) and statistical analysis methods.
• Experience supporting vehicle programs from concept through production launch.
• Proficiency in finite element analysis (FEA) tools such as NASTRAN, ABAQUS, and OptiStruct.
• Demonstrated experience applying FEA tools for structural design analysis, including linear statics, modal, buckling, fatigue, and/or nonlinear analysis.
• Hands-on experience using OptiStruct and modeFRONTIER (or similar tools) for structural optimization, including topology, topography, size, and shape optimization.
• Experience with multi-disciplinary design optimization (MDO) processes and workflows.
• Familiarity with pre/post-processing tools (e.g., HyperMesh, HyperView, ANSA) for model building and results interpretation.
• Understanding of automotive structural design requirements, including durability, crashworthiness, and NVH considerations.
• Working knowledge of manufacturing processes and their impact on structural design (e.g., stamping, casting, joining methods).

Nice To Haves

• Master's degree in a relevant engineering discipline preferred.
• Strong analytical and problem-solving skills with attention to detail.
• Ability to interpret and communicate complex technical results to both technical and non-technical stakeholders.
• Experience with scripting or automation (e.g., Python, MATLAB, or tool-specific scripting languages) is a plus.
• Excellent verbal and written communication skills.
• Ability to work effectively in a cross-functional, fast-paced team environment.

Responsibilities

• Perform linear and nonlinear finite element analysis on automotive body structures, chassis components, and subsystems to evaluate strength, stiffness, durability, NVH, and crashworthiness performance.
• Apply CAE tools throughout the design cycle to support design decisions, identify potential structural issues early, and recommend design improvements.
• Conduct structural topology, topography, size, and shape optimization studies to achieve mass reduction targets while meeting performance and manufacturing constraints.
• Build and refine finite element models (meshing, material assignment, boundary conditions, load cases) for complex structural assemblies.
• Utilize multi-disciplinary optimization (MDO) processes to balance competing performance requirements such as mass, stiffness, durability, and cost.
• Correlate CAE predictions with physical test data and refine modeling methods/assumptions to improve simulation accuracy.
• Collaborate cross-functionally with design engineers, test engineers, and program managers to communicate analysis results and recommendations.
• Document analysis methodologies, assumptions, and results in technical reports and design review presentations.
• Support root-cause investigations for structural performance issues identified during testing or field use.
• Stay current with industry best practices, emerging simulation methods, and software capabilities in structural CAE and optimization.

Benefits

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care 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: Entry Level