FEA Engineer

HSM • Cranberry Township, OH

4d

About The Position

The FEA Engineer develops and executes finite element analyses to evaluate product performance. The role builds, solves, and interprets linear and nonlinear models using appropriate materials, loads, constraints, contacts, connections, and mesh strategies. Analyses may cover static strength, modal, dynamic, vibration, fatigue, thermal, buckling, contact, and durability needs.

The engineer verifies model accuracy through mesh convergence studies, sensitivity checks, hand calculations, and other methods, and evaluates likely failure modes. In partnership with design engineers, the role assesses geometry, materials, joints, welds, bolted connections, and load paths, recommending improvements to performance, cost, and manufacturability. It also supports test planning, compares predictions with physical test results, and refines models where meaningful differences arise.

The position contributes to design reviews, failure investigations, root-cause analysis, and corrective actions. It prepares clear reports and presentations documenting methods, assumptions, results, limitations, risks, and recommended actions, while maintaining traceable analysis records. The engineer also develops reusable modeling approaches, templates, and workflows and automates repeatable tasks where appropriate. Limited travel may be required for design reviews, testing, manufacturing activities, and collaboration at other company locations.

Requirements

• Bachelor’s degree in mechanical engineering, aerospace engineering, civil engineering, or a related engineering discipline.
• Demonstrated experience applying finite element methods to product or structural engineering problems and translating requirements into appropriate analysis plans.
• Proficiency with at least one commercial FEA solver and its pre- and post-processing tools.
• Strong understanding of solid mechanics, material behavior, structural dynamics, fatigue, numerical methods, meshing, boundary conditions, and solution strategies.
• Ability to interpret engineering drawings, material specifications, product requirements, and physical test data.
• Working knowledge of ISO 9001 and experience supporting automotive quality-system requirements.
• Clear technical communication, effective cross-functional collaboration, and ability to manage competing priorities and own deliverables.

Nice To Haves

• Master’s degree in a related engineering discipline.
• Automotive or commercial vehicle experience, particularly with structural components, seating, mechanisms, durability, or vehicle interiors.
• Experience with ANSYS, Abaqus, NASTRAN, LS-DYNA, OptiStruct, HyperMesh, or comparable platforms.
• Experience with advanced analysis methods such as nonlinear materials, large deformation, complex contact, composites, welds, bolted joints, explicit dynamics, fracture mechanics, optimization, or probabilistic analysis.
• Experience correlating simulations with strain-gage, modal, vibration, durability, or other physical test data.
• Familiarity with CAD, product lifecycle management systems, IATF 16949, and VDA 6.3.
• Scripting or workflow automation experience using Python, MATLAB, or solver-specific tools.

Responsibilities

• Develop and execute finite element analyses, including building, solving, and interpreting linear and nonlinear models.
• Perform static strength, modal, dynamic, vibration, fatigue, thermal, buckling, contact, and durability analyses based on product and program needs.
• Verify model accuracy using mesh convergence studies, sensitivity checks, hand calculations, and other verification methods; evaluate likely failure modes.
• Partner with design engineers to evaluate geometry, materials, joints, welds, bolted connections, and load paths, and recommend improvements to performance, cost, and manufacturability.
• Support test planning, compare simulation predictions with test results, and refine models to address meaningful differences.
• Contribute to design reviews, failure investigations, root-cause analysis, and corrective actions.
• Prepare reports and presentations documenting analysis methods, assumptions, results, limitations, risks, and recommended actions; maintain traceable analysis records.
• Develop reusable modeling approaches, templates, and workflows, and automate repeatable tasks where appropriate.
• Travel as needed to support design reviews, testing, manufacturing activities, and collaboration at other company locations.

Benefits

• Affordable medical, dental, and vision insurance plans, including an innovative global healthcare option for qualified participants.
• 401(k) with company match, fully vested from day one.
• Three weeks of vacation and nine company-paid holidays.
• Free on-site medical clinics for employees and covered dependents.
• 24/7 Teladoc access with no copay.
• Tuition reimbursement, professional development assistance, and career growth opportunities.
• Discounts with HSM partners, including Dollywood Parks & Resort and Verizon Wireless.

What This Job Offers

• Job Type: Full-time