Crash Simulation Engineer

RECARO Aircraft Seating; Fort Worth (TX); On-site; USD 110,000 - 140,000; Full time

Job summary

RECARO Aircraft Seating seeks a Design Validation Engineer II, responsible for independently executing structural and crashworthiness validation for seating systems. You will lead analysis models, assess worst-case loads, and drive design robustness through predictive simulations and data-driven judgment.

The role requires strong numerical analysis skills (FEA/LS-DYNA), correlation with test evidence, and collaboration with design teams for certification programs and new product development.

Qualifications

• B.S. degree in Aerospace/Mechanical Engineering with 4+ years’ experience in aircraft interior products; Master’s preferred with 2+ years’ experience.
• Experience in certification processes is a plus.
• Internship experience is preferred, but not required.
• Strong written and verbal communication skills.

Responsibilities

• Execute structural design validation using classical methods, advanced FEA, and physical test evidence.
• Perform linear and non-linear static analysis and dynamic crash simulations (e.g., 14G / 16G) with LS-DYNA.
• Develop, own, and maintain finite element models with proper boundary conditions and loads.
• Correlate physical test results with analytical models to validate assumptions.
• Provide guidance to certification programs on critical load cases and worst-case conditions.
• Drive design improvements by evaluating load paths, margins of safety, and failure modes.
• Collaborate with design teams to influence early design decisions.
• Review drawings, MRB dispositions, concessions, and design deviations.
• Witness qualification, certification, and abuse tests and assess acceptance criteria.
• Prepare and review technical analysis summaries and substantiation documents.

Skills

Organizational skills

Self-motivation

Deadline sensitivity

Detail-oriented

Independent learner

Team collaboration

Effective communication

Ethical judgment

Professionalism

Education

B.S. in Aerospace/Mechanical Engineering

M.S. in Aerospace/Mechanical Engineering

Tools

ANSYS

LS-DYNA

NA SUSA?

CATIA V4/V5

Job description

Description

Job Type

Full-time

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

• 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