Senior CAE engineer

dexmate; Colorado; On-site; USD 110,000 - 170,000; Full time

Job summary

Dexmate is seeking a Senior CAE Engineer to join its Robotics team in Colorado. You will design and validate mechanical systems for next‑gen manipulation robots, using high‑fidelity FEA/CAE tools and close collaboration with mechanical, electrical, controls, software, and manufacturing teams.

You will lead simulations, refine designs, and drive experimental validation to ensure performance, durability, and manufacturability across local projects.

Qualifications

• Designed and analyzed mechanical systems using FEA/CAE tools across various scales.
• Strong fundamentals in mechanics, dynamics, and materials.
• Experience with both implicit and explicit FEA methods.
• Ability to translate analysis into actionable design recommendations.
• Experience validating models with experiments and data correlation.
• Excellent communication and collaboration across disciplines.

Responsibilities

• Develop and analyze finite element models for robotic systems and assemblies.
• Run static, dynamic, structural, and MBD simulations to meet performance requirements.
• Guide design teams with insights based on rigorous CAE results.
• Optimize designs to reduce weight while preserving stiffness and reliability.
• Define load cases for manipulation tasks and real-world operations.
• Validate FEA models via experiments and iterate from results.
• Develop CAE workflows, best practices, and documentation for scaling.

Skills

Solid mechanics

Structural dynamics

Material science

Independent problem solving

Cross-disciplinary collaboration

Education

Bachelor's degree in Mechanical/Aerospace/Applied Mechanics or related field

Master’s degree in related field (optional)

PhD in designing/analyzing mechanical systems (advantage)

Tools

Abaqus

ANSYS

LS-DYNA

COMSOL

OptiStruct

Job description

What You'll Do

As a CAE Engineer on the Dexmate Robotics team, you will be at the forefront of designing and validating mechanical systems for our next-generation manipulation robots. You'll guide design decisions using high-fidelity finite element models grounded in sound engineering principles, working closely with mechanical, electrical, controls, software, and manufacturing teams to bring unprecedented robotic capabilities to life.

Core Responsibilities:

• Develop and analyze comprehensive finite element models for robotic systems, from individual components to full assemblies

• Conduct static, dynamic, structural, and multi-body dynamics (MBD) simulations to evaluate performance against key requirements for strength, stiffness, durability, and manipulation accuracy

• Guide mechanical design teams with actionable insights and design direction based on rigorous analysis

• Optimize structural designs to minimize weight while maximizing stiffness, reliability, and performance under real-world operational loads

• Define and analyze load cases for manipulation tasks, impacts, handling scenarios, and day-to-day operations

• Validate FEA models through experimental testing and iterate based on physical performance data

• Challenge traditional CAE methods and pioneer more efficient, accurate approaches for robotic systems

• Collaborate with controls engineers to understand dynamic load profiles and system-level performance requirements

• Support root cause analysis and failure investigation for production issues

• Develop CAE workflows, best practices, and documentation to scale analysis capabilities across the team

What You'll Bring

Required Qualifications:

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Applied Mechanics, or related field with 5+ years of experience OR Master’s degree with 3+ years of experience OR PhD in designing and analyzing mechanical systems using FEA and CAE tools

• 3+ years of experience in designing and analyzing mechanical systems using FEA and CAE tools
• Strong fundamentals in solid mechanics, structural dynamics, and material science
• Proficiency in CAE software (Abaqus, ANSYS, LS-DYNA, COMSOL, OptiStruct, or equivalent)
• Experience with both implicit and explicit finite element analysis
• Demonstrated ability to conduct static, dynamic, and durability analyses
• Strong understanding of mechanical design principles and ability to translate analysis into actionable design recommendations
• Experience with experimental validation methods and correlation between simulation and physical testing
• Excellent communication skills and ability to collaborate effectively across multidisciplinary teams
• Self-motivated problem solver who can work independently on challenging technical problems

Preferred Qualifications:

• Advanced degree (MS/PhD) in Mechanical Engineering or related field
• Experience in robotics, automation, or mechatronics industries
• Proficiency with multi-body dynamics simulation (ADAMS, MuJoCo, PyBullet)
• Experience analyzing aluminum structures, composites, and advanced materials
• Knowledge of advanced joining methods (adhesives, welding, mechanical fasteners)
• Expertise in non-linear analysis, contact mechanics, and material characterization
• Proficiency in programming/scripting for automation (Python, MATLAB)
• Experience with CAD software (SolidWorks, OnShape, CATIA, NX, etc.)
• Familiarity with structural dynamics, vibration analysis, and modal testing
• Experience with thermal-structural coupling and multi-physics simulations
• Understanding of manufacturing processes and design for manufacturability
• Knowledge of fatigue analysis and life prediction methodologies