Mechanical Engineer - Structural Simulation

DoorDash USA•Oakland, CA

13h•$139,400 - $205,000

About The Position

DoorDash Labs is seeking a Senior Structural Simulation Engineer (Level IC5) to serve as the structural analysis authority for its next-generation robotic platform. The role owns structural finite element analysis (FEA) across vehicle architecture, including chassis systems, suspension, closures, and sensor enclosures. The work focuses on future-forward designs from early concept through production-intent refinement and physical test-to-simulation correlation. The engineer will lead early architectural exploration, define vehicle load cases, and help select and operationalize the simulation software ecosystem, including commercial commitments for CAE tools. The role performs structural analyses and guides mechanical design decisions to optimize strength-to-weight ratios before prototype tooling. It also partners with physical test teams to improve simulation predictive accuracy and communicates actionable design guidance to engineers and leadership.

Requirements

At least 7 years of hands-on structural FEA and mechanical simulation experience, or an MS/PhD and at least 4 years of relevant experience.
Experience focused on structural integrity, stiffness, fatigue life, and dynamic loading.
A demonstrated record analyzing moving vehicle architectures, such as automotive body-in-white, chassis frames, suspensions, structural battery enclosures, robotics, drones, or high-performance mobility platforms.
Advanced proficiency with industry-standard finite element solvers; ANSYS Mechanical/Workbench is strongly preferred, while Abaqus, OptiStruct/HyperMesh, or LS-DYNA are also considered.
Understanding of solver theory, element formulations, and convergence troubleshooting.
Strong mathematical and classical mechanics fundamentals, including the ability to validate stress distributions and shear loads with hand calculations.
Ability to work independently in early-stage product definitions with fluid requirements and sparse documentation, making timely decisions with technical conviction.
Ability to communicate complex analysis results clearly to mechanical design engineers and leadership.

Nice To Haves

Experience establishing or transitioning a company’s CAE software stack from scratch.
Background in topology optimization, lightweighting cast or extruded aluminum structures, or composite material modeling.
Experience running durability and fatigue analyses on systems subject to rough-road, curb-strike, or cyclic vibrational abuse.
Working familiarity with CAD tools such as NX, SolidWorks, or Creo for rapid geometry defeaturing and design iteration.

Responsibilities

Lead structural concept validation for a ground-up robotic platform and run trade studies with chassis, suspension, and closures engineers.
Evaluate, select, and operationalize the primary CAE/FEA software stack, with emphasis on ANSYS-based suites, and work with vendors on capabilities and technical fit.
Formulate structural load cases, fatigue histories, stiffness benchmarks, and failure criteria for dynamic ground vehicle environments.
Perform static, dynamic, modal, durability, and fatigue analyses on structural enclosures, cast and sheet-metal subframes, linkages, and moving mechanisms.
Partner with physical test teams to correlate strain gauge, modal shaker, and dynamic field-testing data with simulation models.
Guide mechanical design decisions and CAD geometry toward optimized strength-to-weight ratios before prototype tooling.
Translate FEA results, fatigue curves, and deflection limits into actionable guidance for mechanical design engineers and leadership.