Senior CAE Crash Engineer: Automate & Optimize Safety

LER TechForce; Raymond (OH); On-site; USD 110,000 - 150,000; Full time

Benefits offered by this job

401 K with match

Short-term & Long-term disability

Life insurance

Employee Assistance Program

Employee Discounts

Technical Training & Leadership Dev

Job summary

LER TechForce is seeking a Senior CAE Crash Engineer to join our client in Raymond, OH on site. You will build and run crash simulations for BIW, use LS-DYNA, ANSA, and other CAE tools, and validate models against test data to meet FMVSS, ECE, and NCAP standards.

The role emphasizes automation, scripting in Python/MATLAB/VBA, and applying AI/ML techniques to optimize designs and CAE workflows, collaborating with body structure and safety engineers to improve crash performance.

Qualifications

• BS Degree or higher in Mechanical Engineering with a minimum of 8+ years of industry experience in using and developing CAE methods.
• Experience with CAE full vehicle crash analysis.
• Proficiency with full vehicle crashworthiness simulations related to front/side and component level, using LS-DYNA and ANSA.
• Familiarity with automotive safety standards (FMVSS, ECE, NCAP) required.
• Familiarity with modeFRONTIER or iSight is a significant advantage.
• Experience with other CAE software such as Nastran, Abaqus, Hypermesh and proficiency with programming language software such as Matlab, Python, and VBA are desired.

Responsibilities

• Build and run crash simulations of the vehicle body-in-white (BIW), including full-vehicle, subsystem, and component models.
• Simulate frontal, side, and other crash events using LS-DYNA.
• Use ANSA to prepare and modify finite element models, including meshing, connections, materials, and model setup.
• Analyze crash results to identify structural weaknesses, deformation patterns, intrusion, energy absorption, and potential safety issues.
• Work with body structure and safety engineers to recommend design changes that improve crash performance.
• Compare simulation results against physical crash-test data to validate and improve the CAE models.
• Ensure simulations support requirements from FMVSS, ECE, and NCAP crash-safety standards.
• Develop 1D/3D CAE models and improve simulation methodologies and processes.
• Create automation tools and scripts to reduce the amount of manual work involved in building, running, and analyzing simulations.
• Use Python, MATLAB, or VBA to automate repetitive CAE tasks and process large amounts of simulation data.
• Potentially apply AI/ML techniques to CAE workflows—for example, predicting crash performance, optimizing designs, or identifying the best design parameters without running hundreds of full simulations.
• Use optimization tools such as modeFRONTIER or iSight to evaluate multiple design configurations and identify an optimized structure.
• Work with other CAE tools such as Abaqus, Nastran, and HyperMesh as needed.
• Correlate CAE predictions with physical testing, identify differences, and improve the accuracy of the simulation models.

Skills

Crash simulations

LS-DYNA

ANSA

Python

MATLAB

VBA

AI/ML CAE

Optimization tools

CAE methodologies

Cross-functional collaboration

Education

Bachelor's degree in Mechanical Engineering

Tools

Abaqus

Nastran

HyperMesh

modeFRONTIER

iSight

Job description

LER TechForce is seeking a Senior CAE Crash Engineer to join our client in Raymond, OH on site. You will build and run crash simulations for BIW, use LS-DYNA, ANSA, and other CAE tools, and validate models against test data to meet FMVSS, ECE, and NCAP standards.

The role emphasizes automation, scripting in Python/MATLAB/VBA, and applying AI/ML techniques to optimize designs and CAE workflows, collaborating with body structure and safety engineers to improve crash performance.