CAE Engineer – Piston Structures & Durability

generalmotors; Warren (MI); Hybrid; USD 90,000 - 120,000; Full time

Benefits offered by this job

Hybrid work model

Relocation benefits available

Job summary

General Motors in Warren, MI seeks a CAE Engineer to support piston structures and durability within Global Virtual Engineering. You will translate engineering questions into physics-based analyses and deliver clear design recommendations.

The role emphasizes independent work, cross-functional collaboration, and ongoing automation improvements using Python, MATLAB, and Excel/VBA to speed up decision-making and reduce design risk.

Qualifications

• Bachelor’s degree in Mechanical, Automotive, Aerospace or Materials Eng or related field.
• Experience applying CAE/FEA to structural, durability, thermal-structural problems.
• Ability to work independently with limited guidance and exercise judgment.
• Experience defining inputs/boundaries, evaluating model quality, interpreting results.
• Strong written and verbal communication and cross-functional collaboration.

Responsibilities

• Lead piston structural and durability evaluations from problem definition through recommendation.
• Assess piston-related performance across thermal, mechanical, inertia, and other conditions.
• Use appropriate CAE fidelity for decisions, including fast screenings and high-fidelity models.
• Diagnose non-routine issues, perform variation studies, and suggest improvements.
• Prepare concise analysis reports and decision packages for teams and leadership.
• Develop automation and capability improvements using Python/MATLAB/Excel/VBA.

Skills

CAE/FEA experience

Independent work

Written & verbal communication

Cross-functional collaboration

Problem solving

Boundary conditions & inputs

Quality & reliability focus

Education

Bachelor’s in Mechanical/Automotive/Aerospace/Materials Eng

Tools

Abaqus

HyperMesh

FLARE

AVL EXCITE

Job description

Job Description

About the role. We are seeking a CAE Engineer to support piston structures and durability within Global Virtual Engineering. This role converts engineering questions, requirements, and failure modes into physics-based analysis and clear design decisions. The engineer will independently execute moderate-scope work, resolve non-routine technical issues, and partner with program teams, design-release engineers, suppliers, and other virtual-analysis specialists.

Why this role matters. The role helps GM make earlier, higher-confidence decisions on piston and cranktrain hardware by combining structural CAE, engineering judgment, risk-based evaluation, and reusable capability development. The successful candidate will contribute to production program support while improving standard work, automation, and the team’s ability to detect and reduce design risk.

What you will do:

• Lead piston structural and durability evaluations from problem definition through recommendation, including load definition, model setup, analysis execution, post-processing, interpretation, and technical reporting.
• Assess piston and related component performance across thermal, mechanical, inertia, pressure, bore-distortion, clearance, and other relevant operating conditions.
• Use appropriate CAE fidelity for the engineering decision: fast screening methods for broad option spaces and higher-fidelity models for critical risk retirement and design release decisions.
• Diagnose non-routine issues, perform sensitivity and variation studies, identify likely failure mechanisms, and recommend practical design or analysis improvements.
• Connect analysis to requirements, DFMEA failure modes, detection/prevention methods, and qualification evidence so that virtual work directly supports risk reduction.
• Prepare concise, traceable analysis reports and decision packages for program teams, DREs, suppliers, leadership reviews, PPDR/PRTS support, and warranty or field investigations as needed.
• Maintain and improve piston-analysis standard work, procedures, templates, macros, and reusable data practices; identify opportunities to improve cycle time, physics, repeatability, and first-time quality.
• Develop automation and capability improvements using appropriate tools such as Python, MATLAB, Excel/VBA, or comparable scripting and post-processing methods.
• Support benchmarking and method development, including comparison of alternative tools, model fidelity, correlation evidence, and emerging virtual-engineering practices.
• Share knowledge and coach developing engineers or technical partners on analysis methods, standard work, interpretation, and quality expectations.
• Collaborate across piston, rings, connecting-rod, cranktrain, lubrication/tribology, materials, testing, design, and program organizations to deliver customer-focused outcomes.

Required qualifications:

• Bachelor’s degree in Mechanical Engineering, Automotive Engineering, Aerospace Engineering, Materials Engineering, or a related technical discipline; equivalent relevant experience may be considered.
• Professional experience applying CAE, FEA, or comparable engineering simulation methods to structural, durability, thermal-structural, or related mechanical problems.
• Demonstrated ability to work independently with limited guidance, exercise sound engineering judgment, and determine an appropriate course of action within established procedures and practices.
• Experience defining analysis inputs and boundary conditions, evaluating model quality, interpreting results, and communicating limitations, uncertainty, and recommendations.
• Ability to identify and resolve non-routine technical problems and manage moderate-scope work through completion.
• Strong written and verbal communication skills, including the ability to explain technical conclusions to both engineering specialists and broader program audiences.
• Ability to collaborate effectively with cross-functional teams, suppliers, and customers while maintaining accountability for quality, timing, and follow-through.

Preferred qualifications

• Master’s or Ph.D. degree in Mechanical Engineering, Automotive Engineering, Aerospace Engineering, Materials Engineering, or a related technical discipline.
• Experience with piston structures, piston pins, connecting rods, cranktrain components, engine durability, or related powertrain hardware.
• Experience with tools such as Abaqus, HyperMesh, FLARE, AVL EXCITE, or comparable pre-processing, solving, and post-processing environments.
• Knowledge of piston failure modes and performance topics such as safety factors, thermal loading, bore distortion, skirt contact/scuffing, land clearance, piston noise, pin behavior, or fatigue.
• Experience with DFMEA, risk-based evaluation planning, design variation/sensitivity studies, qualification evidence, or virtual–physical correlation.
• Experience developing or maintaining engineering standard work, analysis procedures, Excel/VBA tools, Python/MATLAB scripts, automation, or reusable engineering workflows.
• Experience working with production programs, supplier technical issues, warranty/field investigations, or design changes under timing pressure.
• Experience applying artificial intelligence or machine learning to engineering workflows—such as surrogate modeling, reduced-order modeling, design-space exploration, optimization, and predictive analytics—and using design synthesis methods to generate, evaluate, and down-select component or system concepts.

Location: Hybrid. This role is categorized as hybrid. This means the successful candidate is expected to report to the Global HQ Warren MI three times per week, at minimum [or other frequency dictated by the business].

Relocation: This role MAY be eligible for relocation benefits.

The selected candidate will be required to travel <25% for this role. Relocation benefits are available for candidates who qualify under company policy. The position is subject to export control restrictions and requires the successful candidate to be a U.S. Person (U.S. citizen, U.S. permanent resident, asylee or refugee).

About GM

Our vision is a world with Zero Crashes, Zero Emissions and Zero Congestion and we embrace the responsibility to lead the change that will make our world better, safer and more equitable for all.

Why Join Us

We believe we all must make a choice every day – individually and collectively – to drive meaningful change through our words, our deeds and our culture. Every day, we want every employee to feel they belong to one General Motors team.

Benefits Overview

From day one, we're looking out for your well-being–at work and at home–so you can focus on realizing your ambitions. Learn how GM supports a rewarding career that rewards you personally by visiting Total Rewards resources.

Non-Discrimination and Equal Employment Opportunities (U.S.)

General Motors is committed to being a workplace that is not only free of unlawful discrimination, but one that genuinely fosters inclusion and belonging. We strongly believe that providing an inclusive workplace creates an environment in which our employees can thrive and develop better products for our customers.

All employment decisions are made on a non-discriminatory basis without regard to sex, race, color, national origin, citizenship status, religion, age, disability, pregnancy or maternity status, sexual orientation, gender identity, status as a veteran or protected veteran, or any other similarly protected status in accordance with federal, state and local laws.

Accommodations

General Motors offers opportunities to all job seekers including individuals with disabilities. If you need a reasonable accommodation to assist with your job search or application for employment, email us or call us at 1-800-865-7580. In your email, please include a description of the specific accommodation you are requesting as well as the job title and requisition number of the position for which you are applying.