Sr. Staff Structural Simulation Engineer

Rivian and VW Group Technology • Palo Alto, CA

27d

About The Position

As a Senior Staff Structural Simulation Engineer, you will lead structural and thermo-mechanical risk management for advanced vehicle electronics through high-fidelity numerical simulations. You will define critical design requirements for integrated PCB layouts, enclosures, and cooling architectures to ensure aggressive hardware reliability targets are met. Your role involves establishing material characterization protocols and sophisticated model correlation to maintain world-class simulation fidelity. You will serve as a technical authority, driving strategic cross-functional decisions and leading complex root-cause analysis for pioneering electrical hardware. Ultimately, you will guide multidisciplinary teams to ensure engineering excellence and the success of next-generation vehicle systems.

Requirements

• Masters Degree in Mechanical/Aerospace Engineering or equivalent; PhD preferred.
• 8-10 years (Ph.D) / 12-15 years (M.S.) of relevant industry experience working on problems in Applied Structural Mechanics for IC packages and electronics assemblies.
• Solid understanding of theoretical and experimental structural mechanics with excellent domain knowledge in the following areas: Non-Linear analysis, Explicit Analysis, Linear Dynamics and Vibrations, Coupled Thermal-Structural analysis.
• Demonstrated expertise in IC package (electronics package) design, materials, and common failure Chip-Package Interaction (CPI) driven failure modes across diverse applications, including high-power semiconductors and high-performance compute (e.g., AI and ADAS chips) applications.
• Broad understanding of structural composition and manufacturing of diverse package types, including Ball Grid Arrays (BGAs), System-on-Chip (SoC), and System-in-Package (SiP).
• Strong foundation in FEA solvers, particularly Abaqus and Optistruct, with proven ability to independently set up, execute, and troubleshoot analysis convergence issues.
• Proficient in pre/post processing tools such as Hypermesh, Ansa/Meta, etc.
• Excellent understanding of constitutive models and failure modes in metals, plastics, and elastomers.
• Proficient with using Python/Matlab for running analysis and post-analysis data processing.
• Experience developing and leading other multidisciplinary engineers.
• Excellent communication skills across all functions and levels.
• Excellent documentation practices.
• Fluent written and spoken English.

Responsibilities

• Spearhead structural and thermo-mechanical design risk management for low-voltage electronics assemblies within pioneering vehicle electrical hardware.
• Execute multi-scale numerical simulations (e.g., random vibrations, shock, thermal-cycling) for electronics assemblies to establish and meet aggressive functional performance and reliability targets.
• Define structural risk margins, dictate component selection, and optimize component layout on heterogeneously integrated printed circuit boards, driving significant performance gains.
• Deliver comprehensive design guidance, including setting enclosure stiffness requirements, defining thermal stack-up, optimizing cooling architecture, and specifying material systems to electronics assembly design teams.
• Establish material characterization protocols and manage the centralized simulation material database for critical electronics components, polymers, and elastomers, ensuring simulation fidelity.
• Direct, manage, and validate structural benchmarking activities, including sophisticated model correlation through advanced techniques like sine-sweep testing and high-fidelity strain gauge measurements.
• Provide simulation expertise and strategic support to reliability engineering teams for complex root-cause analysis during rigorous testing and validation cycles.
• Drive critical, cross-functional program decisions and consensus across multidisciplinary engineering teams, serving as a technical authority to ensure unparalleled product and engineering excellence.

Benefits

• Total compensation packages for this position include base salary, eligibility for an annual performance bonus, and eligibility for equity.
• In addition, our benefits package has been designed to support the health and wellness of our employees. Benefit offerings include Flex Time Off, retirement savings plans as well as medical, vision and dental coverage.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior