Crash Simulation Engineer

RECARO Aircraft Seating; Fort Worth (TX); On-site; USD 90,000 - 120,000; Full time

Job summary

RECARO Aircraft Seating in Fort Worth, TX is seeking a Design Validation Engineer II to independently execute structural validation activities for aircraft seating systems.

The role involves advanced numerical analysis, correlation with physical test evidence, and ownership of FE models to support FAA and airframer requirements. Collaboration with design teams and evidence-based substantiation are key to success.

Qualifications

• Four-year degree with 4+ years in aircraft interiors or related field, or Master's with 2+ years experience.
• Experience in finite element analysis and crashworthiness validation for seating systems.
• Ability to hand-calculate reserve factors at limit and ultimate load conditions.
• Knowledge of regulatory certification processes and test correlation.
• Strong communication and teamwork skills are required.

Responsibilities

• Execute structural validation for seating systems using analytical methods and FEA.
• Perform static and dynamic crash simulations (14G/16G) using LS-DYNA and similar solvers.
• Develop and maintain finite element models with appropriate boundary conditions and loads.
• Correlate physical test results with analytical models to substantiate findings.
• Provide guidance on critical load cases and worst-case scenarios for certification.
• Drive design improvements by evaluating load paths and margins of safety.
• Collaborate with design teams to influence early design decisions.
• Review drawings, MRBs, concessions, and design deviations for compliance.
• Witness and evaluate component qualification and abuse load tests.
• Prepare analysis summaries and substantiation documents for certification.

Skills

Organizational skills

Self-motivation

Deadlines driven

Detail-oriented

Independent learner

Team collaboration

Verbal and written communication

Ethical technical judgment

Education

Bachelor's in Aerospace/Mechanical Engineering

Master's in Aerospace/Mechanical Engineering (preferred)

Tools

ANSA

LS-DYNA

LS-PrePost (or equivalent)

ANSYS (desired)

CATIA V4/V5

Job description

Description

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 judgement.

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