Product Design Engineer - Structural FEA Expert

Hark; San Jose (CA); On-site; USD 120,000 - 300,000; Full time

Job summary

Hark is seeking a Product Design Engineer with deep simulation and structural analysis expertise to build durable, manufacturable hardware. You will lead structural, thermal, and dynamic FEA across our hardware portfolio and translate findings into design decisions with product design engineers, industrial designers, and reliability teams.

This hands-on role uses simulation to shape early design choices, develop correlations with physical tests, and optimize weight, stiffness, and thermal

Qualifications

• 8+ years of FEA and structural simulation experience in a consumer hardware, aerospace, medical device, or precision manufacturing environment.
• Expert‑level proficiency in at least one major FEA platform (ANSYS, Abaqus, Nastran, or equivalent); experience with meshing, boundary condition definition, nonlinear materials, and contact modeling.
• Strong mechanical engineering fundamentals in solid mechanics, materials science, heat transfer, and dynamics — with the ability to sanity‑check simulation outputs against first‑principles reasoning.
• Experience performing and interpreting drop, vibration, fatigue, and thermal analysis for physical products.
• Proficiency in 3D CAD (SolidWorks, NX, Creo, or equivalent) and the ability to simplify and prepare geometry for simulation without losing critical structural fidelity.
• Demonstrated track record of closing the loop between simulation predictions and physical test results — including model correlation and iterative refinement.

Responsibilities

• Lead structural, thermal, and dynamic finite element analysis (FEA) across Hark's hardware portfolio — enclosures, mechanical assemblies, flex systems, and interconnects — from concept through design validation
• Develop simulation models and methodologies that accurately predict real‑world performance under drop, vibration, fatigue, thermal cycling, and mechanical load conditions
• Translate FEA findings into actionable design recommendations, collaborating directly with product design engineers to iterate geometry, material selection, and wall thickness before hardware builds
• Own tolerance stack‑up analysis and dimensional management for critical assemblies, identifying risk early and driving resolution through design or process changes
• Define and maintain correlation studies between simulation results and physical test data; continuously improve model accuracy based on empirical feedback from reliability and quality teams
• Partner with Industrial Design and Mechanical Engineering to evaluate design trade‑offs weight, stiffness, thermal performance, and manufacturing constraints — and quantify those trade‑offs analytically
• Support design of experiments (DoE) and design verification (DV) planning, defining simulation‑based pass/fail criteria that map to physical test protocols

Skills

FEA & structural simulation

ANSYS/Abaqus/Nastran

Mechanical engineering fundamentals

Drop/vibration/thermal analysis

CAD familiarity

Model correlation & iteration

Tools

ANSYS

Abaqus

Nastran

SolidWorks

NX

Creo

Job description

Hark is seeking a Product Design Engineer with deep simulation and structural analysis expertise to build durable, manufacturable hardware. You will lead structural, thermal, and dynamic FEA across our hardware portfolio and translate findings into design decisions with product design engineers, industrial designers, and reliability teams.

This hands-on role uses simulation to shape early design choices, develop correlations with physical tests, and optimize weight, stiffness, and thermal