CAE Engineer

Dicastal North America Inc.; Livonia (MI); On-site; USD 75,000 - 95,000; Full time

Job summary

A leading aluminum manufacturing company in Livonia, Michigan, seeks a skilled CAE Engineer to conduct structural analysis and optimize designs for automotive aluminum castings. The ideal candidate will have extensive hands-on experience with FEA simulations and product development processes. Responsibilities include designing aluminum components, developing simulations, and collaborating with cross-functional teams. This dynamic role offers advancement in a fast-paced industry.

Qualifications

• 3-5 years of experience in Manufacturing, Process, or Industrial Engineering.
• Experience in CAE/FEA analysis and product design.
• Knowledge of Quality Management Systems such as IATF 16949.

Responsibilities

• Design and optimize aluminum castings using CAD software.
• Develop and execute FEA simulations for structural analysis.
• Collaborate with cross-functional teams to support product development.

Skills

FEA simulation

Product design

Aluminum casting optimization

Technical documentation

Communication skills

Education

Bachelor's or Master's Degree in Mechanical or Aerospace Engineering

Tools

Altair HyperWorks

OptiStruct

nCode

FEMFAT

ABAQUS

CAD software (e.g., CATIA, Siemens NX, SolidWorks)

Microsoft Office Suite

Job description

Overview

Summary: We are seeking a skilled and motivated CAE Engineer with strong product design capabilities to perform structural analysis and contribute directly to the design of automotive aluminum castings. The ideal candidate will possess extensive hands-on experience in both FEA simulation and the product development process, using industry-standard tools such as Altair HyperWorks, OptiStruct, nCode, FEMFAT, ABAQUS, and CAD software (e.g., CATIA, Siemens NX, or SolidWorks). This role requires end-to-end involvement—from concept design and optimization to validation and reporting—ensuring performance, durability, and manufacturability of components.

Responsibilities

• Design and optimize aluminum castings using CAD software, integrating functional performance, manufacturability, and process constraints.
• Develop and execute FEA simulations including static, dynamic, fatigue, and nonlinear analyses using tools such as HyperWorks, OptiStruct, and ABAQUS.
• Perform fatigue analysis using nCode or FEMFAT, including load spectrum processing and material fatigue curve development.
• Lead lightweighting and structural optimization initiatives using OptiStruct and related tools to meet performance and mass reduction targets.
• Interpret CAE results and translate findings into clear, actionable design recommendations to improve component performance and durability.
• Create detailed technical reports and visual presentations using Microsoft PowerPoint, clearly communicating analysis methodology and results.
• Present simulation outcomes to cross-functional teams and stakeholders, ensuring alignment on design direction and technical decisions.
• Collaborate closely with design, manufacturing, and quality teams to support robust, end-to-end product development and validation.
• Occasional business travel to China and Mexico

Qualifications

• Bachelor’s or Master’s Degree in Mechanical Engineering, Aerospace Engineering, or a related field.
• 3-5 years of experience in Manufacturing, Process, or Industrial Engineering position
• Knowledge and experience with AutoCad
• Experience in CAE/FEA analysis and product design. Preferably in automotive industry.
• Proficiency in Altair Hyperworks, OptiStruct, N-code/Femfat, and ABAQUS.
• Experience working in a global engineering environment.
• Experience writing procedures and work instructions
• Ability to create and deliver high quality technical documents and presentations
• Familiar with Quality Management Systems Standards such as IATF 16949
• Computer Skills (Word, Excel, PowerPoint, Minitab, Visio, Project).
• Working knowledge of word processing and spreadsheet software in use.
• Experience with industrial equipment
• Strong written and oral communication skills in English with all levels of the company
• Ability to understand and carry out complicated oral or written instructions
• Mandarin Chinese proficiency (written/verbal) is a plus.

Organizational Culture

• Work safely and follow rules and guidelines for safe work
• Reporting to work on time and with a positive attitude
• Responsible for staying focused on tasks at hand
• Being responsible for work performance and completing tasks throughout the day
• Maintains a good working relationship with co-workers
• Support a positive and steady workflow through the company
• Works with a sense of urgency when needed
• Support, coach or mentor co-workers when needed
• Positively support change throughout the company

Physical Work Conditions

• Must be able to work in a hot environment
• Must be able to lift and move aluminum wheels of varying weight
• Must be able to lift 50 – 65 pounds
• Must be able to stand and walk for up to 12 hours per day
• Must be able to wear personal protective equipment when required

Note: This job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.