Senior FEA/ Structural Analysis Engineer

Frey Consulting Group; Hagerstown (MD); On-site; USD 90,000 - 130,000; Full time

Benefits offered by this job

Health, dental, vision insurance

Company paid life insurance

PTO and retirement plan 401k

HSA program available

Job summary

Productive Resources in Hagerstown, MD seeks a Senior FEA/Structural Analysis Engineer to lead advanced simulations of mobile-equipment components. The role covers static, dynamic, nonlinear, and fatigue analyses, with close collaboration to design and manufacturing teams to improve strength, weight, and durability.

The ideal candidate has 5+ years in structural FEA, strong engineering mechanics knowledge, and hands-on model development experience.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Civil or Structural Engineering.
• 5+ years of structural FEA experience or equivalent.
• Experience with linear static and modal analysis; nonlinear analysis preferred.
• Ability to translate real-world operating conditions into engineering load cases.

Responsibilities

• Perform advanced FEA of structural components and systems (booms, frames, load-bearing parts).
• Develop finite element models: geometry prep, meshing, materials, boundary conditions, loads, validation.
• Conduct static/dynamic analyses and modal studies to assess performance.
• Analyze telehandler structures and components with explicit analysis for impact and protective structures.
• Interpret results and identify high-stress regions, deformations, and potential failures.
• Collaborate with design engineers to optimize strength, weight, durability, and cost.
• Run MBD simulations to evaluate machine motion and dynamic loading.
• Incorporate flexible bodies into multibody simulations when needed.
• Prepare stress reports and technical documentation for regulatory approvals.

Skills

FEA

Structural analysis

Multibody dynamics

Fatigue analysis

Mechanical engineering

Problem solving

Education

Bachelor’s degree in Mechanical Engineering, Civil or Structural Engineering

Tools

MSC Nastran

MSC Apex

MSC Patran

HyperWorks

OptiStruct

Radioss

MSC Adams/View

MathCAD Prime

nCode

CAEFatigue

Job description

Senior FEA/ Structural Analysis Engineer

Productive Resources (www.productiveresources.com) is seeking a candidate to be part of our engineering team for our customer's facility in Hagerstown, MD. As a member of our team, the selected candidate will be an experienced FEA/Structural Analysis Engineer joining our engineering team and serving as a technical expert in structural analysis, finite element analysis, multibody dynamics, and fatigue analysis. This position will support the development and validation of mobile equipment, including booms, scissor lifts, vertical lifts, telehandlers, and other material-handling equipment. The ideal candidate is an analytical problem solver who can take a design from preliminary engineering calculations through advanced simulation and provide actionable recommendations to improve structural performance, durability, and safety. This role will work closely with design engineering and other technical teams to evaluate components and systems under static, dynamic, nonlinear, fatigue, and regulatory loading conditions.

This is a full-time position that is indefinite in duration with the opportunity of professional growth, and additional opportunities within our organization.

Duties:

• Perform advanced Finite Element Analysis (FEA) of structural components and systems, including booms, scissors, vertical structures, frames, and other load-bearing components.
• Develop finite element models, including geometry preparation, meshing, material properties, boundary conditions, load application, and model validation.
• Perform linear static, nonlinear static, modal/normal modes, and dynamic analyses to evaluate structural performance.
• Analyze telehandler structures and components using appropriate finite element methods, including explicit analysis for impact and protective-structure applications.
• Interpret FEA results and identify areas of high stress, excessive deformation, instability, or other potential failure modes.
• Work with design engineers to recommend design modifications and optimize components for strength, weight, durability, manufacturability, and cost.
• Perform Multibody Dynamics (MBD) simulations to evaluate general machine motion, component interactions, dynamic loading, and system behavior.
• Develop and incorporate flexible-body models into multibody simulations where appropriate.
• Extract loads from MBD simulations for use in FEA, component sizing, and structural design.
• Perform classical engineering calculations and preliminary component sizing using MathCAD Prime or similar engineering calculation tools.
• Evaluate regulatory and customer-required load combinations, particularly for Mobile Elevating Work Platforms (MEWPs).
• Prepare engineering calculations, stress reports, and technical documentation supporting regulatory and product approvals.
• Perform fatigue and durability analyses to estimate component life based on expected duty cycles and operating conditions.
• Support correlation and validation of analytical models using physical test data when available.
• Communicate analysis results clearly to engineering teams, management, and other stakeholders.
• Provide technical guidance and expertise on structural analysis methods, modeling practices, and simulation results.

Requirements:

• Bachelor’s degree in Mechanical Engineering, Civil or Structural Engineering, or a related field.
• 5+ years of experience performing structural FEA or a comparable level of advanced engineering analysis experience.
• Strong understanding of engineering mechanics, structural behavior, material properties, stress analysis, and failure modes.
• Hands-on experience developing and interpreting finite element models.
• Experience with linear static and modal analysis; experience with nonlinear analysis is strongly preferred.
• Ability to translate real-world operating conditions into appropriate engineering load cases and boundary conditions.
• Strong analytical, problem-solving, and technical communication skills.
• Ability to work independently on complex engineering problems while collaborating effectively with design and manufacturing teams.

Preferred:

• Experience with MSC Nastran, MSC Apex, MSC Patran, HyperWorks, OptiStruct, or Radioss.
• Experience with MSC Adams/View or another multibody dynamics software package.
• Experience incorporating flexible bodies into multibody simulations.
• Experience extracting dynamic loads for structural FEA and component sizing.
• Experience with MathCAD Prime or similar engineering calculation software.
• Experience with nCode, CAEfatigue, or other fatigue analysis software.
• Experience performing fatigue analysis based on duty cycles.
• Familiarity with MEWP, telehandler, aerial lift, heavy equipment, construction equipment, agricultural equipment, or other off-highway machinery.
• Experience with regulatory or certification-related structural analysis and technical reporting.
• Knowledge of explicit dynamic/impact analysis and protective structure requirements, including FOPS applications.

Why work for Productive Resources?

Productive Resources is a full-service engineering firm with over two decades of experience serving leading global clients. Our expertise is project-based product development and manufacturing engineering support. Our primary focus industries are off highway equipment including agricultural, construction, defense, mining, recreational, industrial, and specialty machines.

We lead with our reputation for quality, teamwork, and innovative solutions. We invest in our people, providing resources and opportunities for ongoing development. Our workplace fosters innovation, prioritizes the well-being of our team, and encourages creativity. Our diverse experience and client base will challenge your technical skills and provide greater opportunities for growth.

• Group Health, Dental and Vision Insurance
• Company Paid Life Insurance
• Voluntary Life, AD&D, and Disability Insurance available
• Voluntary Critical Illness and Accident Insurance available
• Long-Term Disability
• Short-term Disability
• Retirement Savings Account (Traditional 401k & Roth 401k)
• Flexible Spending Plans for Medical Expenses and Dependent Care
• Health Savings Account (HSA) Programs available
• Health Care Flexible Spending Account (FSA) Plan
• Paid Time Off (PTO)
• Health Care Support Program complimentary health advocacy program provides 24/7 assistance.