Lead Physical AI Engineer

Caterpillar; Irving (TX); On-site; USD 148,000 - 240,000; Full time

Benefits offered by this job

Medical benefits

401(k) plan

Health Savings Account (HSA)

Flexible Spending Accounts (FSAs)

Career Development

Job summary

Caterpillar is seeking a Lead Physical AI engineer to develop high-fidelity machine models and digital twins for Caterpillar construction equipment, using NVIDIA Newton, Isaac Sim, Omniverse, and OpenUSD. You will set modeling standards and advance physics-based simulation across the enterprise.

Collaborating with autonomy, robotics, and AI teams, you will enable reinforcement learning, synthetic data generation, and software-in-the-loop validation, driving ROM development and long-term digital

Qualifications

• Bachelor’s, Master’s, or Ph.D. in Mechanical Engineering, Robotics, Mechatronics, Aerospace Engineering, Computer Engineering, or related field.
• 8+ years of experience in simulation, robotics, autonomous systems, digital twins, or machine dynamics.
• Demonstrated expertise in NVIDIA Newton or similar tools and physics simulation.
• Strong knowledge of vehicle dynamics, hydraulics, powertrain, and machine-terrain interaction.
• Proficiency in Python and C++; experience with model development and validation.
• Experience leading technical projects and collaborating across engineering teams.
• Excellent communication and problem-solving skills.

Responsibilities

• Lead NVIDIA Newton technical leadership across the enterprise, defining standards and best practices.
• Develop high-fidelity machine models, ROMs, and physics-based representations for Caterpillar equipment.
• Collaborate with autonomy, robotics, and AI teams to enable reinforcement learning and AI-enabled workflows.
• Establish validation processes and correlate simulations with real-world data and telemetry.
• Drive ROM development, virtual validation, and lifecycle management for scalable deployment.
• Shape technology strategy and long-term roadmaps for digital twins and simulation.

Skills

NVIDIA Newton

Python

C++

Simulation

Robotics

Autonomous systems

Digital twins

Machine dynamics

Vehicle dynamics

Kinematics

Problem solving

Communication skills

Education

Engineering degree

Tools

NVIDIA Isaac Sim

Omniverse

Warp

OpenUSD

ROS2

GitHub Copilot

Job description

Career Area:

Technology, Digital and Data

Job Description:

Your Work Shapes the World at Caterpillar Inc.

When you join Caterpillar, you're joining a global team who cares not just about the work we do – but also about each other. We are the makers, problem solvers, and future world builders who are creating stronger, more sustainable communities. We don't just talk about progress and innovation here – we make it happen, with our customers, where we work and live. Together, we are building a better world, so we can all enjoy living in it.

Help Build the Future of Caterpillar –

At Caterpillar, technology always has a purpose, which is to solve our customers’ toughest challenges. Through Cat Technology, we are solving problems by building the intelligence layer that connects machines, data, and people to make jobsites safer, more productive, and more sustainable. By combining deep domain expertise in physical systems with software, connectivity, autonomy, and AI, we deliver solutions that work in the real world—on real jobsites, at global scale.

Be Part of What’s Next in Autonomous Construction Sites

Construction autonomy is one of the most complex challenges in applied AI, and at Caterpillar, advancements in physical AI, simulation, sensing, and edge computing are turning things that once felt impossible—intelligent machines operating in dynamic jobsites—into reality.

If this work motivates you, we invite you to join our team. Apply today to build the new era of construction autonomy at Caterpillar.

Role Definition

The Lead Physical AI engineer will lead the development of high-fidelity digital twins and machine dynamics models for Caterpillar construction machines. The successful candidate will establish modeling standards, simulation methodologies, and best practices using NVIDIA Newton, Isaac Sim, Omniverse, OpenUSD, and related NVIDIA technologies. The role will bridge machine physics, robotics simulation, autonomy development, and Physical AI initiatives.

Responsibilities

NVIDIA Newton Technical Leadership

The Principal Engineer will serve as Caterpillar's primary subject matter expert for NVIDIA Newton and will provide technical leadership for the adoption and advancement of Newton-based simulation technologies across the enterprise. This individual will evaluate the capabilities of the Newton physics engine, establish modeling standards and development methodologies, and define best practices for creating scalable, reusable machine simulation solutions. The engineer will also work closely with NVIDIA and internal stakeholders to align Newton capabilities with Caterpillar's long-term simulation, autonomy, robotics, and Physical AI strategies.

Machine Dynamics and Physics Modeling

A major responsibility of this role is the development of machine models that accurately represent the behavior, performance, and operational characteristics of Caterpillar construction equipment. The engineer will leverage NVIDIA Newton to model rigid-body dynamics, articulated mechanisms, powertrain systems, hydraulic actuation, tire-ground interaction, and machine-terrain interaction. The role requires developing physics-based representations of machine subsystems and their interactions under realistic operating conditions, enabling accurate simulation of machine mobility, implement operation, material handling, and terrain engagement.

Physical AI, Autonomy, and Robotics Enablement

The engineer will collaborate closely with autonomy, robotics, and AI teams to ensure machine models support advanced applications such as reinforcement learning, synthetic data generation, software-in-the-loop testing, and autonomous system validation. The role will enable integration between machine models, virtual environments, sensor simulation frameworks, and robotics software stacks, creating a simulation ecosystem capable of accelerating the development and deployment of next-generation autonomous machine capabilities.

Model Validation and Correlation

This position will establish validation processes that ensure simulation results accurately represent real-world machine behavior. The engineer will work with domain experts in machine systems, controls, hydraulics, and vehicle dynamics to validate models against engineering analyses, test results, operational data, and machine telemetry. The role will drive continuous improvement in model accuracy, solver robustness, computational efficiency, and simulation credibility to support engineering decision-making and autonomous system development.

Reduced Order Model (ROM) Development

Lead the development of Reduced Order Models (ROMs) for Caterpillar construction machinery by transforming high-fidelity simulation models into computationally efficient representations that support real-time analysis, virtual validation, reinforcement learning, and AI-enabled engineering workflows. The role is responsible for establishing methodologies for ROM creation, validation, deployment, and lifecycle management while ensuring accuracy, scalability, and reusability across Caterpillar construction equipment platforms. The engineer will collaborate with simulation, AI, and product development teams to accelerate design exploration, improve engineering efficiency, and enable next-generation model-based development capabilities.

Research, Innovation, and Technology Strategy

As Caterpillar's technical authority on NVIDIA Newton, the engineer will continuously assess emerging technologies, simulation methodologies, and industry advancements related to physics-based modeling and Physical AI. The individual will identify opportunities to leverage new capabilities within the NVIDIA ecosystem and help define Caterpillar's long-term roadmap for digital twins, virtual product development, machine simulation, and AI-enabled engineering workflows. The role is expected to influence strategic technology decisions while driving innovation across simulation and autonomy initiatives.

Required Qualifications

• Bachelor's, Master's, or Ph.D. in Mechanical Engineering, Robotics, Mechatronics, Aerospace Engineering, Computer Engineering, or a related field.
• 8+ years of experience in simulation, robotics, autonomous systems, digital twins, or machine dynamics.
• Demonstrated expertise in NVIDIA Newton or similar tools, including multibody dynamics, articulated systems, and machine physics simulation.
• Strong knowledge of vehicle dynamics, hydraulics, powertrain systems, kinematics, and machine-terrain interaction.
• Proficiency in Python and C++.
• Experience developing and validating high-fidelity simulation models for complex mechanical systems or the CAE software tools used to build them.
• Experience leading technical projects and collaborating across multidisciplinary engineering teams.
• Excellent communication and problem-solving skills.

Preferred Qualifications

• Hands-on experience with NVIDIA Isaac Sim, Omniverse, Warp, OpenUSD, and Isaac Lab.
• Experience modeling construction machinery equipment
• Experience with ROS2, robotics software, and autonomous system development.
• Experience supporting reinforcement learning, synthetic data generation, or Physical AI initiatives.
• Experience developing digital twins and virtual validation environments.
• Experience using AI code-generation tools like GitHub Copilot

Summary Pay Range:

$147,760.00 - $240,110.00

Benefits:

Subject to plan eligibility, terms, and guidelines. This is a summary list of benefits.

• Medical, dental, and vision benefits*
• Paid time off plan (Vacation, Holidays, Volunteer, etc.)*
• 401(k) savings plans*
• Health Savings Account (HSA)*
• Flexible Spending Accounts (FSAs)*
• Health Lifestyle Programs*
• Employee Assistance Program*
• Voluntary Benefits and Employee Discounts*
• Career Development*
• Incentive bonus*
• Disability benefits
• Life Insurance
• Parental leave
• Adoption benefits
• Tuition Reimbursement

* These benefits also apply to part-time employees

Posting Dates:

Any offer of employment is conditioned upon the successful completion of a drug screen.

Caterpillar is an Equal Opportunity Employer, Including Veterans and Individuals with Disabilities. Qualified applicants of any age are encouraged to apply.