Crash Simulation Engineer

Insight Global; United States; Remote; USD 83,000 - 152,000; Full time

Job summary

Insight Global is seeking experienced Crash CAE / Crash Simulation Engineers for remote, contract-style engineering projects supporting a large US data initiative. Workloads range from 20 to 40+ hours per week, with software licensing and hardware provided as needed.

You'll prep FE models with ANSA/HyperMesh, run LS-DYNA or Radioss simulations, analyze results, and propose design changes for BIW crashworthiness, front/side/rear impacts, roof/rollover.

Qualifications

• Bachelor's Degree in Mechanical, Automotive, or Aerospace Engineering.
• 3–7+ years of CAE/crashworthiness or nonlinear FEA experience.
• Hands-on with ANSA/HyperMesh or similar preprocessing tools.
• Experience using LS-DYNA, Radioss, or similar explicit solvers.
• Experience analyzing frontal/side/rear/BIW crash events.

Responsibilities

• Prepare or modify vehicle FE models using ANSA or HyperMesh.
• Set up and run crash simulations using LS-DYNA or Radioss.
• Analyze deformation, intrusion, loads, stresses, energy absorption, and failures.
• Propose geometry, material, or joining changes and rerun simulations.

Skills

Crash CAE

FEA experience

Remote work capability

Analytical thinking

Education

Bachelor's Degree in Mechanical Engineering

Tools

ANSA

HyperMesh

LS-DYNA

Radioss

Job description

A cutting-edge engineering and AI-driven technology organization is rapidly expanding its U.S.-based engineering contractor network to support one of the largest ongoing engineering data initiatives in the market. Due to continued growth and consistent project volume, the team is seeking experienced Crash CAE / Crash Simulation Engineers with hands-on automotive crashworthiness and finite element modeling experience.

This is a highly flexible, fully remote opportunity designed for experienced engineers looking for either full-time contract work or technical project work alongside a primary position. Engineers can select projects aligned with their expertise and availability, with workloads ranging from 20 to 40+ hours per week. Software licensing and hardware will be provided when necessary.

Crash CAE Engineer / Crash Simulation EngineerEngineers will work on technical projects that replicate real-world vehicle crash and structural analysis scenarios, covering the process from FE model preparation through crash simulation, results analysis, and structural optimization. Projects may involve frontal impact, side impact, rear impact, roof/rollover, and Body-in-White (BIW) structural crashworthiness.

Typical assignments may require engineers to prepare or modify vehicle FE models using ANSA or HyperMesh, including meshing, material assignment, connections, contacts, spot welds, adhesives, and other crash-model setup activities. Engineers will then set up and execute crash simulations using LS-DYNA or OpenRadioss (now called OpenCourant), analyze deformation and intrusion, loads/forces, stresses, energy absorption, and component or material failure, and determine why a structure is not performing as intended.

Engineers may assess structures including rails, crash boxes, bumpers, pillars, rockers, roof rails, crossmembers, floor structures, firewalls, joints, sheet metal, and BIW assemblies. Based on simulation results, they will recommend changes to geometry, material, thickness, reinforcement, or joining strategies and rerun simulations to validate improvements.

Rather than a traditional engineering organization with continuous management oversight, this environment uses structured workflows, automation, and self-service tools. Deliverables go through a robust quality-assurance process before becoming part of larger engineering initiatives. The organization is actively scaling its contributor network, creating opportunities for engineers to take on additional projects and increasingly complex technical work based on performance and expertise.

Must-Haves

• Bachelor's Degree in Mechanical Engineering, Automotive Engineering, Aerospace Engineering, or related engineering discipline
• 3-7+ years of CAE, crashworthiness, vehicle structural analysis, or closely related nonlinear FEA experience
• Hands-on experience building, modifying, or preparing finite element vehicle/structural models using ANSA, HyperMesh, or a comparable preprocessing platform
• Hands-on experience setting up or running crash/impact simulations using LS-DYNA, Radioss, or a comparable explicit dynamics solver
• Experience analyzing at least one of the following: frontal impact, side impact, rear impact, roof/rollover, or BIW structural crash
• Working knowledge of crash-model setup, including meshing, materials, contacts, connections, spot welds, bolts, adhesives, or similar joining methodologies
• Ability to evaluate simulation outputs including structural deformation, intrusion, forces/loads, stresses, energy absorption, and component/material failure
• Experience working with automotive or transportation structures such as BIW, rails, pillars, rockers, crossmembers, floor structures, crash boxes, bumpers, or structural joints
• Ability to interpret crash results and recommend geometry, material, gauge/thickness, reinforcement, or connection changes
• Comfortable working independently in a fully remote, workflow-driven environment with structured QA rather than traditional day-to-day management

Plusses

• Advanced experience with ANSA and/or HyperMesh
• Advanced experience with LS-DYNA and/or Radioss
• Experience correlating CAE crash models with physical crash-test results
• Experience with automotive Body-in-White (BIW), crashworthiness, occupant-compartment integrity, or structural optimization
• Experience supporting an OEM, Tier 1, or Tier 2 automotive supplier, particularly advanced vehicle development programs
• Experience troubleshooting model instability, contact behavior, material failure, connection behavior, or other nonlinear crash-simulation issues
• Experience reviewing or validating simulation/engineering deliverables through formal quality assurance processes
• Senior, Principal, Technical Lead, or Subject Matter Expert background
• Previous participation in AI, engineering simulation, modeling, or engineering data-generation initiatives