Crash Simulation Engineer

Recaro Aircraft Seating Americas, Inc.; Fort Worth (TX); On-site; USD 90,000 - 120,000; Full time

Job summary

Recaro Aircraft Seating Americas, Inc. is seeking a Design Validation Engineer II, a crash simulation specialist responsible for executing structural validation for aircraft seating systems.

You will use advanced FEA, LS-DYNA, and test data to demonstrate compliance with FAA and industry requirements. You will own FE models, perform static and dynamic crash analyses, correlate results with physical tests, and guide certification activities.

Qualifications

• BS or MS in Aerospace/Mechanical engineering with 4+ years in aircraft interior products or related field.
• Experience in structural validation for aerospace seating or interiors is preferred.
• Strong analytical and problem-solving skills; able to work to deadlines.

Responsibilities

• Execute structural validation for seating systems using FEA, LS-DYNA, and physical test evidence.
• Perform linear/non-linear static and dynamic crash simulations (e.g., 14G/16G).
• Develop and maintain FE models with appropriate boundary conditions and material properties.
• Correlate test results with analytical models to support certification substantiation.
• Provide guidance on load cases and worst-case configurations for certification.
• Evaluate load paths, margins of safety, and design robustness across variants.
• Collaborate with design engineering to influence early design decisions.
• Review drawings, MRB dispositions, concessions, and design deviations for compliance.
• Witness component qualification, certification, and abuse tests; assess acceptance criteria.
• Prepare and review technical analysis summaries and substantiation documents.

Skills

Finite element analysis

Crash dynamics

Correlation with test data

Strong communication

Team collaboration

Regulatory certification knowledge

Education

Bachelor's degree in Aerospace/Mechanical engineering

Master's degree in Aerospace/Mechanical engineering

Tools

ANSA

LS-DYNA

CATIA

Ansys

Job description

About this position

Description:

Position Summary: The Design Validation Engineer II \"Crash Simulation Engineer\" is responsible for independently executing structural and crashworthiness validation activities for aircraft seating systems. This role provides specialized technical expertise to demonstrate compliance with FAA, airframer, airline, and internal structural requirements through advanced numerical analysis, classical engineering methods, and correlation with physical test evidence.

The position plays a critical role in certification programs and new product development by owning analysis models, evaluating worst-case loading conditions, and driving design robustness through predictive simulations and data-driven engineering judgment.

Essential Duties and Responsibilities include the following, other duties may be assigned:

• Execute structural design validation for aircraft seating systems to demonstrate compliance with FAA, airframer, airline, and internal requirements using classical analytical methods, advanced finite element analysis (FEA), and supporting physical test evidence.
• Perform linear and non-linear static analysis and dynamic crash simulations (e.g., 14G / 16G conditions) using LS-DYNA and equivalent solvers to assess structural integrity, occupant safety, and certification compliance.
• Develop, own, and maintain finite element models by defining appropriate boundary conditions, material properties, load cases, and modeling techniques to realistically represent certification and operational scenarios.
• Analyze and correlate physical test results with analytical models to validate assumptions, establish confidence in simulation accuracy, and support certification substantiation.
• Provide technical guidance to certification programs through assessment of critical load cases, test configurations, and worst-case structural conditions in accordance with regulatory and customer requirements.
• Drive structural design improvements by evaluating load paths, margins of safety, failure modes, and robustness across multiple configuration variants.
• Collaborate with design engineering teams on development of new components and seat architectures by providing predictive analysis input and validation feedback to influence early design decisions.
• Review and assess engineering drawings, MRB dispositions, concessions, and design deviations by performing structural impact assessments to ensure continued compliance with certification and structural integrity requirements.
• Review and witness component qualification, certification, and abuse load tests by evaluating test plans, setups, and acceptance criteria.
• Author and review technical analysis summaries and engineering substantiation documentation to support certification findings and internal technical reviews.

Requirements:

Education/Experience:

• A minimum of Four-year B.S. degree is required preferably in Aerospace / Mechanical / other engineering with at least 4 years’ experience in aircraft interior products or a Master's degree preferably in Aerospace or Mechanical engineering with at least 2 years’ experience in aircraft interior products.

Technical Skills and Experience Requirements

• Organizational skills, self-motivation, a sense of urgency and sensitivity to deadlines, and detail-oriented style are required.
• Evidence of ability to hand calculate generating reserve factors, at limit and ultimate load conditions using classical methods or methods described by Tom Rhodes.
• Ability to learn independently
• At minimum of 2 years of Finite element analysis experience is needed
• At a minimum 1 year experience in ANSA or similar software and LS-Dyna software is required.
• Knowledge of Ansys software is desired.
• Experience in CATIA V4 or V5 or a similar program desired.
• Experience in Certification is a plus.
• Internship experience is preferred, but not required.
• Good verbal and written communication skills are required.
• The ability to work as part of a team in conjunction with more and or less experienced people.
• Strong ethical persuasion to seek out the truth in a technical situation.
• The wisdom to deal with technical challenges with tack and professionalism