Lead Physical AI Engineer

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

Benefits offered by this job

Medical, dental, and vision benefits

401(k) savings plans

Paid time off

Job summary

Caterpillar Irving, TX is seeking a Lead Physical AI Engineer to develop high-fidelity digital twins and physics-based machine models for construction equipment. You will lead NVIDIA Newton adoption, establish modeling standards, and collaborate across autonomy, robotics, and AI teams.

The role emphasizes reinforcement learning, synthetic data, and software-in-the-loop testing to accelerate AI-enabled engineering workflows while ensuring model validity and performance across real-world scenarios.

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.

Responsibilities

• Lead the development of high-fidelity digital twins and machine dynamics models for Caterpillar construction machines.
• Establish modeling standards, simulation methodologies, and best practices using NVIDIA Newton, Isaac Sim, Omniverse, and OpenUSD.
• Bridge machine physics, robotics simulation, autonomy development, and Physical AI initiatives.
• Develop and validate machine models representing behavior, performance, and operating characteristics.
• Collaborate with autonomy, robotics, and AI teams to support reinforcement learning, synthetic data generation, and software-in-the-loop testing.
• Establish validation processes with domain experts to ensure realism of simulations.

Skills

Python

C++

Project leadership

Communication skills

Robotics

Education

Bachelor’s/Master’s/Ph.D. in Mechanical Engineering/Robotics/Mechatronics/Aerospace/Computer Engineering

Tools

NVIDIA Newton

Isaac Sim

Omniverse

OpenUSD

NVIDIA Warp

Isaac Lab

ROS2

Job description

## Lead Physical AI EngineerApply: Irving, Texas: Full time: Posted 3 Days Ago: R0000395038**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 LeadershipThe 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 CorrelationThis 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) DevelopmentLead 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 - $240,110.00Compensation and benefits offered may vary depending on multiple individualized factors, job level, market location, job-related knowledge, skills, individual performance and experience. Please note that salary is only one component of total compensation at Caterpillar.**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