Principal Structural & CAE Durability Engineer – Battery Systems

HappyGlobal Service; Irvine (CA); On-site; USD 180,000 - 240,000; Full time

Job summary

HappyGlobal Service is seeking a Principal Structural & CAE Durability Engineer to lead structural, fatigue, durability, and CAE analysis for battery module and pack systems. This senior role defines CAE strategy, analysis methodologies, automation, and technology development across battery programs.

You will collaborate with DREs and Mechanical, Electrical, Systems, and Manufacturing teams to ensure designs meet performance, safety, reliability, and manufacturability targets.

Qualifications

• MS or PhD in Mechanical Engineering, Structural Engineering, Solid Mechanics, or a related technical discipline.
• 15+ years of experience in structural, fatigue, and durability CAE analysis, ideally within automotive, battery, or related industrial systems.
• Expert-level experience with FEA/CAE tools such as ABAQUS, HyperWorks / OptiStruct, NASTRAN, LS-DYNA, ANSA, nCode.
• Strong technical background in fatigue, NVH, optimization/DOE, and multi-physics structural analysis.
• Proven experience developing CAE automation tools and standardized engineering processes.
• Programming/scripting experience for CAE automation using Python, C/C++, Tcl/Tk, VBA, or similar languages.
• Demonstrated ability to define technical strategy, mentor engineers, and lead cross-functional technical collaboration.
• Strong written and verbal communication skills, including experience presenting technical findings to engineering and program leadership.

Responsibilities

• Lead structural, fatigue, durability, and NVH CAE analysis for battery module and pack designs.
• Define and drive the structural CAE strategy, methodologies, and technology roadmap across battery engineering programs.
• Develop CAE automation tools and standardized engineering workflows to improve modeling quality, efficiency, and repeatability.
• Apply optimization, DOE, and AI/ML techniques to support battery module and pack design decisions.
• Present analysis results, design recommendations, and structural risk assessments to engineering and program leadership.

Skills

FEA/CAE analysis

Leadership

Cross‑functional collaboration

Technical communication

Python scripting

Education

Master's or PhD in Mechanical Engineering or related field

Tools

ABAQUS

HyperWorks/OptiStruct

NASTRAN

LS-DYNA

ANSA

nCode

Teamcenter

NX

Job description

Reports to: Director, Battery Engineering

About our client

Our client is a global leader in next-generation energy storage and electric vehicle technologies, specializing in lithium batteries and related systems.

About the Role

The Principal Structural & CAE Durability Engineer will lead structural, fatigue, durability, and CAE analysis for battery module and pack systems.

This is a senior technical leadership position with responsibility for defining CAE strategy, analysis methodologies, automation, and technology development across battery engineering programs.

You will work closely with Design Release Engineers (DREs) and cross-functional teams including Mechanical, Electrical, Systems, and Manufacturing Engineering to ensure battery structural designs meet performance, safety, reliability, and manufacturability requirements.

The ideal candidate combines deep expertise in FEA-based structural and durability analysis with experience developing CAE automation tools and applying AI/ML, optimization, and DOE techniques to engineering problems.

Key Responsibilities

• Lead structural, fatigue, durability, and NVH CAE analysis for battery module and pack designs.
• Perform and guide analysis related to:
• Random PSD and sine vibration
• Vibration fatigue
• Weld fatigue, including spot, laser, staple, and MIG welds
• Thermal cycling, creep, and fatigue of polymeric components
• Define and drive the structural CAE strategy, methodologies, and technology roadmap across battery engineering programs.
• Develop CAE automation tools and standardized engineering workflows to improve modeling quality, efficiency, and repeatability.
• Apply optimization, DOE, and AI/ML techniques to support battery module and pack design decisions.
• Partner with DREs and cross-functional engineering teams to identify and resolve structural risks.
• Review and validate FEA models, structural calculations, and engineering analysis reports.
• Analyze structural performance of battery components including trays, cell tabs, BDU, ICB, side plates, and brackets.
• Lead root-cause investigations related to structural failures, test results, and field issues.
• Evaluate and implement CAE software, platforms, and engineering tools.
• Provide technical leadership, mentorship, and analysis review guidance to structural and CAE engineers.
• Present analysis results, design recommendations, and structural risk assessments to engineering and program leadership.
• Continuously improve engineering standards, simulation methodologies, and structural design practices.

Required Qualifications

• MS or PhD in Mechanical Engineering, Structural Engineering, Solid Mechanics, or a related technical discipline.
• 15+ years of experience in structural, fatigue, and durability CAE analysis, ideally within automotive, battery, or related industrial systems.
• Expert-level experience with FEA/CAE tools such as:
• ABAQUS
• HyperWorks / OptiStruct
• NASTRAN
• LS-DYNA
• ANSA
• nCode
• Strong technical background in fatigue, NVH, optimization/DOE, and multi-physics structural analysis.
• Proven experience developing CAE automation tools and standardized engineering processes.
• Programming/scripting experience for CAE automation using Python, C/C++, Tcl/Tk, VBA, or similar languages.
• Demonstrated ability to define technical strategy, mentor engineers, and lead cross-functional technical collaboration.
• Strong written and verbal communication skills, including experience presenting technical findings to engineering and program leadership.

Preferred Qualifications

• PhD in Mechanical Engineering or Solid Mechanics.
• Direct experience with battery module and/or battery pack structural design and durability analysis.
• Experience applying AI/ML techniques to CAE modeling, simulation, or design optimization.
• Experience with Teamcenter, NX, or similar PLM/CAD integration environments.
• Patents, technical publications, or industry recognition in structural or CAE engineering.
• Design for Six Sigma or related quality/process certification.