Senior Structural Mechanics & FEA Engineer

ACL Digital; Pune District; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

ACL Digital seeks an experienced Senior Structural Mechanics & FEA Engineer to lead static/dynamic analyses, vibration assessments, and design optimization for complex assemblies. You will translate physical systems into accurate numerical models and validate results with test data.

In this role, you will collaborate with design teams, apply FEA best practices in Ansys, and drive reliability under dynamic operating environments while mentoring junior engineers.

Qualifications

• 5 years of professional experience in structural analysis and FEA simulation in product design, manufacturing, automotive, or aerospace sectors.
• Strong fundamentals in structural mechanics, dynamics and vibration theory.
• Proficient in CAD for geometry prep and mid-surfacing.

Responsibilities

• Lead end-to-end static, nonlinear, and transient FEA to assess strength and safety margins.
• Develop precise FBDs to map loads, boundaries, stresses and reactions.
• Perform modal, harmonic, and random vibration analyses to avoid resonance.
• Collaborate with design teams to recommend structural optimizations.
• Translate FEA outputs into clear engineering reports and validate with tests.

Skills

FEA

Ansys

Free Body Diagrams

Vibration Analysis

Dynamic Analysis

CAD

Education

Bachelor's or Master's in Mechanical/Aerospace/Structural Engineering

Tools

Creo

SolidWorks

UG NX

CATIA

Job description

Role Summary

We are seeking an experienced Senior Structural Mechanics & FEA Engineer with 5 years of core industry experience to lead structural integrity, static/dynamic analysis, and vibration assessments for mechanical components and complex assemblies. In this role, you will apply fundamental mechanical principles to translate physical systems into accurate numerical models, evaluate load paths, and optimize structural designs for dynamic operational environments.

Key Responsibilities

• Free Body Diagrams & Analytical Physics: Develop precise Free Body Diagrams (FBDs) to map complex load vectors, boundary conditions, internal stresses, and reaction forces across mechanical systems prior to numerical simulation.
• Finite Element Analysis (FEA): Perform end-to-end static, non-linear (geometric, material, and contact), and transient structural analyses using Ansys to evaluate component strength, stress concentrations, and safety margins.
• Vibration & Dynamics Assessment: Conduct modal, harmonic, dynamic, and random vibration analyses to prevent resonance, mitigate fatigue, and ensure structural durability under dynamic operating environments.
• Design Optimization: Work closely with mechanical design teams to interpret FEA results, identify failure modes, and recommend structural modifications (e.g., lightweighting, ribbing, material selection) to meet performance criteria.
• Validation & Documentation: Translate complex FEA outputs into actionable engineering reports; correlate numerical simulation results with physical test data to refine and validate simulation methodologies.

Key Technical Requirements

• Core Competencies: Strong theoretical background in structural mechanics, solid mechanics, material behavior, dynamics, and vibration theory.
• FEA Software Proficiency: 5 years of hands-on expertise in Ansys (Ansys Mechanical, Workbench) for meshing, solver setup, post-processing, and structural optimization.
• Analytical Modeling: Demonstrated mastery in construct hand calculations and Free Body Diagrams (FBD) to validate FEA simulation outputs.
• Structural Analyses Expertise: Proven track record in stress analysis, fatigue life estimation, buckling analysis, and tolerance/deflection evaluation.
• Vibration Analysis: Practical experience in solving real-world vibration problems (modal analysis, sine sweep, random vibration, shock load simulations).

Qualifications

• Bachelors or Master’s degree in Mechanical, Aerospace, or Structural Engineering.
• 5 years of professional engineering experience in structural analysis and FEA simulation within product design, manufacturing, automotive, or aerospace sectors.
• Proficiency with CAD software (e.g., Creo, SolidWorks, UG NX, or CATIA) for geometric preparation and mid-surfacing.