Technical Specialist - CAE Mold Flow

Ford • Dearborn, MI

10d • $112,680 - $212,760 • Hybrid

About The Position

Moldflow CAE Technical Specialist focuses on advanced injection molding simulation to optimize part and tool development for Exterior Systems, ensuring alignment with corporate requirements. The successful candidate will lead, perform, and audit Moldflow simulations, transforming models into high-fidelity finite element representations to accurately predict performance and identify cost-saving opportunities across all development stages.
Key responsibilities include problem-solving molding-related issues, authoring new design rules and acceptance criteria for molded materials, and providing critical technical support to D&R, PD Finance, Purchasing, and Cost Optimization teams. Furthermore, this position involves reviewing and validating supplier simulations, interpreting CAE and physical test results to develop feasible countermeasures, and establishing strong correlations between virtual and physical testing. Active participation in local and global forums to share emerging methodologies, teaching Moldflow courses, and maintaining a forward-looking mindset on new technologies are also essential aspects of this role.

Requirements

• BS in Engineering or a related field
• Engineering degree (Science Materials, Polymer Materials, Mechanical, Mechatronics, desirable) or related disciplines with coursework in Finite Element Methods.
• 8+ years - Strong ability to interpret injection molding reports and identify improvements in part design, tool design, and process parameters.
• Skilled at distinguishing high value simulation reports from those lacking technical rigor or sufficient data.
• Ability to understand and analyze MFR log files.
• Capable of identifying high value UDB files and ensuring they are correctly applied in simulations.
• Expertise in detecting simulations that deviate from internal quality standards.
• Strong ability to integrate injection molding results into structural FEM workflows to produce accurate CAE predictions reflecting manufacturing effects.
• Deep understanding of part design beyond CAD geometry and Excel datasets, applying real world manufacturability principles.
• Excellent at summarizing and presenting technical results to cross functional teams in a clear and concise manner.
• Strong practical problem-solving approach, bridging simulation and real world production constraints.
• Independent, highly organized, self-motivated, persistent, and goal oriented.
• Able to work effectively both independently and collaboratively across global teams.
• Strong emotional intelligence and proven company loyalty.
• Effective communicator with strong presentation skills.
• Creative thinker capable of rapidly assessing problems and identifying feasible solutions.
• Highly adaptable and able to manage multiple tasks in dynamic environments.
• Demonstrated leadership with the ability to motivate, influence, negotiate, and align diverse stakeholders.
• Strong self-learning ability and willingness to adopt new tools early.

Nice To Haves

• MS or Ph. D. degree preferred.
• DFSS Green Belt (or Equivalent certification in statistical and optimization tools and techniques) preferred.
• 10+ years professional experience in injection molding simulation and CAE, preferably within the automotive industry.
• Extensive knowledge of the plastic injection molding process for automotive components.
• Extensive experience performing injection-molding simulations, including fill, pack, cooling, and warp analyses on complex parts, using midplane and full 3D mesh models.
• Experience simulating mold inserts, heater cartridges, induction coils, and mold blocks to analyze thermal performance.
• Extensive expertise in simulating hot-runner systems, including valve programming to optimize gating, flow distribution, and overall process performance.
• Proven experience delivering Class A surface parts, with expertise in managing material finishes and a background in lighting acceptance criteria.
• Experience with injection molding machine setup: process parameters and startup procedures. Knowledge of scientific molding principles and process control strategies.
• Strong understanding of injection molding simulation variables and their engineering impact.
• Excellent understanding of injection molded part design fundamentals.
• Solid engineering knowledge of mechanical, structural, and polymer science concepts ((rheology, physical and thermal properties)
• Understanding of injection mold manufacturing processes, tool steels, and machining considerations.
• Experience with major CAE packages such as Moldflow, Moldex3D, ANSA, HyperWorks, Nastran, Abaqus, Radioss, LSDyna, and Digimat; experience with Teamcenter, CATIA, Siemens NX, and Autodesk Inventor.
• Familiarity with vehicle level CAE analyses, such as gravity sag, sun load, firmfeel, aero loads, and hood seal resistance.
• Knowledge of automotive product development processes and validation frameworks (e.g., GPDS).
• Strong grounding in heat transfer, polymer rheology, and how processing conditions influence material behavior.
• Familiarity with statistical methods and optimization techniques.
• Proven ability to develop, enhance, or innovate analysis reporting formats.
• Ability to translate abstract physical principles and mathematical models into practical design decisions; teaching experience preferred.
• Field oriented mindset with strong real-world problem-solving ability.

Responsibilities

• Lead, perform, and audit advanced injection molding simulations to identify efficiency opportunities in part and tool development, ensuring alignment with ESOW/MSOW requirements.
• Lead problem solving for issues related to molding
• Improve or author new requirements and design rules and acceptance criteria for molded materials
• Execute and review Moldflow simulation analyses for exterior system components, delivering robust design insights and complete technical documentation across all development stages.
• Create, modify, and transform injection molding simulation models into high-fidelity finite element representations that accurately predict Exterior Systems performance, following corporate standards and procedures. Perform detailed audits of Moldflow models for accuracy and compliance.
• Support Ford D&R, PD Finance, Purchasing, and Cost Optimization teams by reviewing the complete ED&T mountain chart to validate assumptions, identify efficiency opportunities, and define costeffective simulation targets based on program and commodity design scope.
• Provide technical support to D&R teams during T0 and DCV events, ensuring that tool performance correlates with simulation predictions and meets signoff requirements.
• Participate in local and global forums to share emerging methodologies, new procedures, and innovative approaches to injection molding simulation.
• Support the ELD organization by teaching Moldflow courses as part of the Plastics Curriculum for PD, Purchasing, Finance, and GVT teams.
• Interpret Moldflow, CAE, and physical test results to develop feasible countermeasures that ensure compliance with system and component level requirements. Establish strong correlation between simulation and physical testing.
• Perform and audit injection molding simulations at a level of detail appropriate to each development milestone, ensuring efficiency and consistency with design output needs.
• Review and validate supplier injection molding simulations, ensuring Exterior Systems targets are met through a consistent DV plan based on DVM methodologies and aligned with corporate requirements.
• Collaborate with global CAE teams and physical testing groups to improve simulation methods and enhance correlation between virtual and physical results.
• Maintain a forward looking mindset by staying current with emerging technologies, tools, and best practices in injection molding simulation.

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