Senior Manufacturing Simulation Engineer

General Motors; Warren (MI); Hybrid; USD 110,000 - 140,000; Full time

Job summary

General Motors is seeking a highly technical Manufacturing Process Analyst to drive physics-based analyses for propulsion systems, including engines, motors, and batteries. You’ll join a team that provides modeling support for development, troubleshooting, and validating future technology initiatives.

The role requires strong fundamentals, experience with FEA/CFD, and the ability to work in ambiguous environments while mentoring junior engineers. Hybrid work with periodic site visits is expected.

Qualifications

• Bachelor's degree in Mechanical Engineering, Materials Engineering, Manufacturing Engineering, or a related engineering discipline.
• Master's degree or PhD preferred.
• 3+ years of professional experience applying engineering simulation methods, including FEA, CFD, or related modeling tools, with 5+ years preferred.
• Experience developing, interpreting, validating, or applying engineering models to solve technical problems.
• Strong analytical and problem-solving skills.
• Ability to work independently in environments with incomplete information and evolving requirements.
• Strong technical communication and collaboration skills.

Responsibilities

• Partner with manufacturing, plant, product design, materials, and process engineering teams to define complex technical problems and analysis objectives.
• Conduct FEA, CFD, thermal, structural, and multiphysics analyses to identify root causes and develop practical solutions.
• Investigate heat treatment, material phase transformation, thermal gradients, residual stress, distortion, ductility, and other material and process behaviors.
• Apply simulation to manufacturing processes such as casting, machining, assembly, welding, and fluid flow.
• Develop analysis approaches independently, including selection of appropriate physics, assumptions, boundary conditions, material models, and solution methods.
• Perform research and literature reviews to support model development and technical recommendations.
• Create and improve analysis methods and workflows using tools such as Abaqus, Altair HyperWorks, STAR-CCM+, Dante, NX CAD, and Python.
• Automate preprocessing, solver execution, post-processing, and reporting where appropriate.
• Correlate simulation results with test, inspection, plant, experimental, or production data.
• Post-process and interpret results, prepare technical presentations, and communicate conclusions to internal customers and leadership.
• Provide technical guidance, train others, and mentor or coordinate the work of a small group of engineers as needed.

Skills

Analytical skills

Independent work

Technical communication

Education

Bachelor's degree in Mechanical/MET related engineering

Master's degree or PhD preferred

Tools

Abaqus

HyperWorks

STAR-CCM+

Dante

NX CAD

Python

Job description

General Motors is seeking a highly technical Manufacturing Process Analyst to drive physics-based analyses for propulsion systems, including engines, motors, and batteries. You’ll join a team that provides modeling support for development, troubleshooting, and validating future technology initiatives.

The role requires strong fundamentals, experience with FEA/CFD, and the ability to work in ambiguous environments while mentoring junior engineers. Hybrid work with periodic site visits is expected.