Senior CAE Durability & Structural Lead, EV Battery Systems

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

Job summary

HappyGlobal Service in California, Irvine, seeks a Principal Structural & CAE Durability Engineer to lead structural integrity, fatigue, and durability analysis for battery module and pack systems in EV programs.

This senior role owns the CAE strategy, methods, and automation roadmap, mentoring engineers and partnering with DREs and cross-functional teams to ensure designs meet performance and reliability targets.

Qualifications

• PhD or MS in Mechanical Engineering, Structural Engineering, Solid Mechanics, or related field.
• 15+ years in structural, fatigue, and durability CAE analysis in automotive or battery systems.
• Expert-level proficiency in FEA/CAE tools: ABAQUS, HyperWorks/OptiStruct, NASTRAN, LS-DYNA, ANSA, and nCode.
• Strong background in fatigue, NVH, optimization/DOE, and multi-physics structural analysis.
• Proven track record developing CAE automation tools and standard engineering processes.
• Experience with scripting for CAE automation (Python, C/C++, Tcl/Tk, VBA).
• Ability to define technical strategy, mentor engineers, and drive cross-functional collaboration.
• Excellent written and verbal communication; experience presenting to leadership.

Responsibilities

• Lead structural, fatigue, durability, and NVH CAE analysis for battery module and pack designs.
• Define and drive the CAE analysis strategy and technology roadmap across programs.
• Develop automation tools and standard workflows to improve CAE quality and efficiency.
• Apply optimization, DOE, and AI/ML to guide design decisions.
• Mentor CAE engineers and present results to program leadership.
• Review and validate FEA models and analysis reports for battery components.

Skills

CAE leadership

Mentoring

Cross-functional collaboration

Python scripting

AI/ML for CAE

DOE/Optimization

FEA proficiency

Education

PhD in Mechanical Engineering

MS in Mechanical Engineering

Tools

ABAQUS

HyperWorks/OptiStruct

NASTRAN

LS-DYNA

ANSA

nCode

Job description

HappyGlobal Service in California, Irvine, seeks a Principal Structural & CAE Durability Engineer to lead structural integrity, fatigue, and durability analysis for battery module and pack systems in EV programs.

This senior role owns the CAE strategy, methods, and automation roadmap, mentoring engineers and partnering with DREs and cross-functional teams to ensure designs meet performance and reliability targets.