Structural CAE Engineer - Crash & Safety Job Details | Career - avl.com

AVL; Coventry; On-site; GBP 35,000 - 48,000; Full time

Job summary

A leading automotive technology firm in the UK is seeking a Structural CAE Engineer to conduct crash and safety simulations. The role requires a solid engineering background, preferably in mechanical or automotive engineering, and proficiency in LS-DYNA among other tools. You will engage in diverse projects, contributing to the development of innovative powertrain technologies. A competitive salary between £35,000 - £48,000 is offered, with various employee benefits including a pension scheme and private medical insurance.

Benefits

EV Lease Scheme

Flexi-time

Private Medical Insurance

Cycle to Work Scheme

25 days holiday per year

Pension scheme

Life Assurance

Professional membership

Qualifications

• Experience in structural CAE simulations for electric powertrains.
• Strong focus on LS-DYNA for crash simulations.
• Excellent analytical skills for technical recommendations.

Responsibilities

• Perform data processing and analysis for powertrain concepts.
• Contribute to design and development of powertrain components.
• Present results and recommendations to stakeholders.

Skills

Structural CAE simulations

Problem-solving skills

Analytical skills

Communication skills

Education

Bachelor’s or Master’s degree in a relevant engineering area

Tools

LS-DYNA

HyperMesh

ANSA

Job description

Overview

AVL Powertrain UK Ltd offers a job in the United Kingdom (GB) as Structural CAE Engineer - Crash & Safety. AVL Powertrain UK is currently seeking a highly motivated engineer with a pro-active attitude, excellent problem-solving skills and solid technical engineering background. You will join a highly dynamic team working on new technologies in the fields of electrification and powertrain performance in the automotive industry.

You will join the CAE & Data Science Team and co-operate closely with our established engineering team, whilst taking responsibility within our internal and customer projects. Your role will be focused on linear & non-linear fatigue, and structural simulation for powertrains/vehicles.

Our engineers are typically exposed to multiple different projects during their career working with us. The role is therefore particularly suited to people who will enjoy the opportunity to gain experience in new areas and who can rapidly self-start, combining creative and analytical problem-solving skills.

Responsibilities

• Support system analysis projects, across internal and customer opportunities covering a range of battery and powertrain concepts
• Perform data processing and analysis, with reporting to internal and customer teams and management
• Contribute to the design and development of powertrain components by performing structural simulations, impact analysis and optimization studies to enhance product performance
• Perform crash and safety simulations using LS-DYNA for vehicle structures, battery enclosures, and restraint systems
• Develop and refine finite element models using HyperMesh, ANSA, or similar tools and interpret simulation results and provide actionable design recommendations
• Collaborate with design, test, and regulatory teams to ensure compliance with FMVSS, Euro NCAP, and other standards
• Present results and recommendation of analysis to stakeholders
• Support internal AVL presentations and participate in trainings and knowledge exchange

Your profile

Essential

• Bachelor’s or Master’s degree in a relevant engineering area (Mechanical, Automotive, Electric/Electronics)
• Experience in structural CAE simulations for electric powertrains and batteries, model correlation & validation against test data
• Experience in CAE simulation with a strong focus on LS-DYNA
• Proficiency in pre/post-processing tools (e.g., HyperMesh, LS-PrePost, ANSA)
• Solid understanding of crash mechanics, material modeling, and occupant safety
• Familiarity with global crash regulations and test procedures
• Excellent analytical skills with ability to make clear technical recommendations across multifunctional disciplines
• Self-starter with the ability work with high level instruction
• Ability to communicate technical information effectively
• Flexibility to work across multiple projects/locations
• Open minded, flexible ‘can do’ attitude

Preferable

• Experience in Automotive battery pack impact and crash simulations and analysis
• Experience in performing damage tolerance analysis to estimate fracture life and perform steady state and transient thermal analysis for automotive components
• In addition to the essential structural CAE experience/awareness of other CAE simulation and tools (e.g. MATLAB, Simulink, GT Suite, Python, AVL CRUISE M) across virtual development, verification, and validation

We offer

• EV Lease Scheme (Salary Sacrifice)
• Flexi-time (applies to most roles)
• Private Medical Insurance and Health Cash Plan
• Cycle to Work Scheme
• 25 days holiday per year (increases by 1 day annually up to the max. of 28 days)
• Special occasion leave (eligibility after probation, subject to conditions)
• Pension scheme
• Life Assurance and Income Protection Insurance
• One paid professional membership annually

If an offer of employment is made, applicants are required to undergo a DBS check. Offers of employment are subject to a satisfactory DBS check and the company reserves the right to withdraw its offer in the event that the applicant has unspent criminal convictions.

Annual Remuneration: Due to UKVI compliance requirements, we are obligated to state the annual gross salary (full-time) for this position. The salary range is between £35,000 - £48,000 and we will offer market-conforming remuneration taking qualifications and professional experience into account.

Job posted on: 17/09/2025

Closing date: 17/10/2025

We look forward to receiving your details for the unique opportunity to join our growing, high-tech, international team.