Research Engineer

Ford Motor • Dearborn, MI

4d • Hybrid

About The Position

This position is for a Generalist-Integrator at the cutting edge of "Smart Manufacturing" and "Industry 4.0". The role involves weaving the results of one simulation into the starting conditions of the next, creating an end-to-end Digital Thread. This ensures that the final structural analysis is based on a realistic model that has been virtually formed, welded, and baked, rather than a perfect CAD model. The ideal candidate will be a Digital Architect of Physics with coding ability and a solid grasp of non-linear mechanics to architect a Manufacturing Digital Thread spanning Metal Forming (Stamping/Casting), Body Construction, and Paint. The role requires collaboration with domain experts to translate material physics into automated CAD/CAE applications, bridging engineering silos to optimize structural attributes and minimize dimensional variation.

Requirements

• Bachelor’s degree in Mechanical Engineering, Material Science and Engineering or Computer Science and Engineering
• 2+ years of experience in industry and graduate study developing and applying skills in architectural data integration, CAE-based virtual manufacturing, solid mechanics, material behavior, statistical variation methods, and GD&T
• Highly proficient in Python, MATLAB, or C++ for linking disparate data formats
• Experience with PLM systems such as Catia V5/V6, 3DEXPERIENCE (3DX)
• Knowledge of virtual manufacturing using CAE suites such as Ansys Minerva, Abaqus, LS-DYNA, or Nastran, Simufact, ESY Sysweld

Nice To Haves

• Strong foundation in Solid Mechanics (elasticity, plasticity), material deformation, and thermal-mechanical behavior.
• Deep understanding of stress-strain behavior, anisotropy in sheet metal, and phase transformations during welding or baking.
• Proficiency of Monte Carlo simulations and Six Sigma principles to handle "variation" as a statistical input rather than a single deterministic value.
• Knowledge of Geometric Dimensioning and Tolerancing to manage dimensional "stack-ups."

Responsibilities

• Research and design custom 3DEXPERIENCE (3DX)/Catia tools using C++ and Python.
• Architect linkage programs to automate data flow between simulation solvers (Hypermesh, LS-DYNA, AutoForm) and CAD environments.
• Ensure developed tools and data pipelines are robust and computationally efficient, minimizing latency and maximizing throughput for large-scale simulation data.
• Lead statistical sensitivity studies and Design of Experiments (DOE) to optimize manufacturing robustness.
• Validate the accuracy and performance of 3DX implementations.
• Partner with Ford subject matter experts in forming, joining, and surface science to develop a unified digital twin for stamping, structural casting, and coating workflows.
• Streamline simulation run-times and automate data processing to enable 100% in-house feasibility validation and rapid design iterations.

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: Senior
• Number of Employees: 5,001-10,000 employees