Exterior Structures CAE Engineer

Ford Motor; Dearborn (MI); Hybrid; USD 74,000 - 166,000; Full time

Benefits offered by this job

Medical coverage

Flexible work model

Vehicle discount

Tuition assistance

Paid time off

Job summary

Ford Motor Company is seeking an Automotive Structures CAE Engineer in Dearborn, MI. You will perform linear and nonlinear FEA on body structures, support design decisions, and optimize mass and performance through topology and size optimization.

You will collaborate with design, test, and program teams to ensure durability, crashworthiness, NVH, and manufacturability while staying current with CAE practices and software capabilities.

Qualifications

• Bachelor’s degree in mechanical engineering or related field.
• 3 years of relevant automotive structural CAE experience.
• Experience with FEA tools (NASTRAN, ABAQUS, OptiStruct).
• DOE and statistical analysis familiarity.
• Experience supporting vehicle programs from concept to production.
• Proficiency with HyperMesh/HyperView/ANSA for modeling.
• Experience with MDO workflows.

Responsibilities

• Perform linear and nonlinear FEA on body structures to evaluate strength and stiffness.
• Apply CAE tools to support design decisions and issue identification.
• Conduct topology, topography, size, and shape optimization for mass reduction.
• Build and refine finite element models with proper boundary conditions.
• Correlate CAE predictions with test data and improve accuracy.
• Collaborate with design, test, and program teams to communicate results.
• Document methodologies and results in reports.
• Support root-cause investigations for structural issues.
• Stay current with industry CAE practices and software capabilities.

Skills

FEA tools

Structural analysis

Unibody design

DOE & stats

Topology optimization

Cross-functional collab

Education

Bachelor's in Mechanical Engineering

Master's preferred

Tools

HyperMesh

HyperView

ANSA

modeFRONTIER

Python scripting

Job description

We made history and now we work to transform the future – for our customers, our communities and our families. You'll see your work on the road every day, helping people move freely and pursue their dreams. At Ford, you can build more than vehicles. Come build what matters.

Product Development uses design thinking & user experience methods to deliver breakthrough products and services that delight our customers. We bring innovative, exciting, and sustainable ideas to life.We have opportunities around the world for you to contribute to advancements in autonomy, electrification, smart mobility technologies, and more!

We are seeking a talented and detail-oriented Automotive Structures CAE Engineer to join our engineering team. In this role, you will be responsible for performing finite element analysis (FEA) and structural optimization to support the design, development, and validation of Unibody and Body-on-Frame structures and components. You will work closely with design, test, and program engineering teams to deliver lightweight, durable, and safety-compliant structural solutions.

Responsibilities

What you'll do...

Perform linear and nonlinear finite element analysis on automotive body structures, chassis components, and subsystems to evaluate strength, stiffness, durability, NVH, and crashworthiness performance.

Apply CAE tools throughout the design cycle to support design decisions, identify potential structural issues early, and recommend design improvements.

Conduct structural topology, topography, size, and shape optimization studies to achieve mass reduction targets while meeting performance and manufacturing constraints.

Build and refine finite element models (meshing, material assignment, boundary conditions, load cases) for complex structural assemblies.

Utilize multi-disciplinary optimization (MDO) processes to balance competing performance requirements such as mass, stiffness, durability, and cost.

Correlate CAE predictions with physical test data and refine modeling methods/assumptions to improve simulation accuracy.

Collaborate cross-functionally with design engineers, test engineers, and program managers to communicate analysis results and recommendations.

Document analysis methodologies, assumptions, and results in technical reports and design review presentations.

Support root-cause investigations for structural performance issues identified during testing or field use.

Stay current with industry best practices, emerging simulation methods, and software capabilities in structural CAE and optimization.

Qualifications

You'll have...

• Bachelor’s degree in mechanical engineering, Automotive Engineering, or a related engineering discipline (required).
• 3 years of relevant industry experience in automotive or related structural CAE applications (adjust based on level: entry, mid, or senior).
• Familiarity with design of experiments (DOE) and statistical analysis methods.
• Experience supporting vehicle programs from concept through production launch.
• Proficiency in finite element analysis (FEA) tools such as NASTRAN, ABAQUS, and OptiStruct.
• Demonstrated experience applying FEA tools for structural design analysis, including linear statics, modal, buckling, fatigue, and/or nonlinear analysis.
• Hands-on experience using OptiStruct and modeFRONTIER (or similar tools) for structural optimization, including topology, topography, size, and shape optimization.
• Experience with multi-disciplinary design optimization (MDO) processes and workflows.
• Familiarity with pre/post-processing tools (e.g., HyperMesh, HyperView, ANSA) for model building and results interpretation.
• Understanding of automotive structural design requirements, including durability, crashworthiness, and NVH considerations.
• Working knowledge of manufacturing processes and their impact on structural design (e.g., stamping, casting, joining methods).

Preferred

• Master's degree in a relevant engineering discipline preferred.
• Strong analytical and problem-solving skills with attention to detail.
• Ability to interpret and communicate complex technical results to both technical and non-technical stakeholders.
• Experience with scripting or automation (e.g., Python, MATLAB, or tool-specific scripting languages) is a plus.
• Excellent verbal and written communication skills.
• Ability to work effectively in a cross-functional, fast-paced team environment.

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a changemaker, a technical expert, a culture builder…or all of the above? No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

This position is a salary grade 6-8 and ranges from $74,300 - $166,200.

Final determination of salary grade will be based on candidate's skills and experience, and base salary will be set within the applicable range according to job scope, responsibility and competitive market value.

Visa sponsorship is not available for this position.

Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.

We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status or protected veteran status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1-888-336-0660.

This position is hybrid. Candidates who are in commuting distance to a Ford hub location may be required to be onsite four or more days per week.

Job Info

• Job Identification 67774
• Job Category PD Operations and Quality
• Posting Date 08/10/2026, 02:59 PM
• Apply Before 08/25/2026, 12:00 AM
• Degree Level Bachelor's Degree or equivalent
• Job Schedule Full time
• Locations 20901 Oakwood Blvd, Dearborn, MI, 48124, US (Hybrid)