Sr. CAE Engineer - Durability Methods

polaris; Wyoming (MN); On-site; USD 109,000 - 144,000; Full time

Job summary

Polaris Inc. seeks a Durability Engineering Leader to drive FEA-based simulation methods across global teams, advancing durability to improve vehicle performance and development efficiency.

You will mentor engineers, develop modeling guidelines, and integrate test data to standardize CAE workflows. This role focuses on leadership, innovation, and scalable methods within an agile vehicle development environment.

Qualifications

• Bachelor's degree in Mechanical Engineering required.
• Minimum 6 years in durability analysis, structural simulation, or CAE methods development with focus on FEA.
• Expertise with FEA tools (Abaqus, ANSYS, OptiStruct or similar).
• Strong fatigue analysis, nonlinear simulation, load case development and durability.
• Experience scripting/automation in Python or TCL.
• Ability to collaborate across global teams and drive standardized processes.

Responsibilities

• Lead development, validation, and deployment of advanced durability methods using CAE/FEA tools.
• Drive innovation in FEA-based simulation, including fatigue, nonlinear, transient analysis, and complex joint modeling.
• Standardize CAE workflows and define load case strategies for global teams.
• Develop modeling guidelines, load generation methods, and post-processing procedures.
• Collaborate with MBD and test teams to improve data integration and fidelity.
• Improve correlation between simulations and physical test results; refine methods.

Skills

Leadership

Communication

Python scripting

TCL scripting

Education

Bachelor's degree in Mechanical Engineering

Tools

Abaqus

ANSYS

OptiStruct

Job description

At Polaris Inc., we have fun doing what we love by driving change and innovation. We empower employees to take on challenging assignments and roles with an elevated level of responsibility in our agile working environment. Our people make us who we are, and we create incredible products and experiences that empower us to THINK OUTSIDE.

Position Overview:

You will provide technical leadership in the development and advancement of durability engineering methods to support next-generation off-road vehicle design. In this role, you will lead the application of FEA-driven simulation techniques to improve predictive accuracy, efficiency, and consistency across engineering teams. You will collaborate with global stakeholders to standardize processes, integrate physical test data, and influence early-stage product development decisions. You will also mentor engineers and promote adoption of best practices and scalable methodologies. This role offers the opportunity to shape durability engineering approaches and drive meaningful impact on product performance and development effectiveness.

Key Responsibilities:

• Lead the development, validation, and deployment of advanced durability methods using commercial CAE and FEA tools.
• Drive innovation in FEA-based simulation approaches, including fatigue analysis, nonlinear simulation, transient response, and complex joint modeling.
• Identify gaps in current CAE workflows and establish standardized processes to support global engineering consistency.
• Define and implement modeling guidelines, load case strategies, and post-processing procedures to improve scalability and repeatability.
• Develop and standardize load generation approaches, durability events, and virtual use cases.
• Collaborate with MBD and test teams to improve integration of loading data and enhance simulation fidelity.
• Improve correlation between simulation models and physical test results through validation and method refinement.
• Develop and implement automation strategies to streamline CAE workflows using scripting tools.
• Apply durability methodologies early in vehicle architecture development to influence design decisions and performance targets.
• Provide technical leadership, mentorship, and subject matter expertise to engineering teams.

Desired Competencies:

• Technical / Functional Expertise: You apply the required technical or professional knowledge to perform your role effectively and stay current within your area of expertise.
• Critical Thinking: You analyze information objectively, evaluate options, and apply sound judgment to solve problems and make informed decisions.
• Leadership: You inspire, guide, and empower others to achieve their best by setting clear direction, fostering trust, and creating an environment where people feel supported, motivated, and accountable for delivering results.

Qualifications:

• Bachelor's degree in Mechanical Engineering or a related field.
• Minimum of 6 years of experience in durability analysis, structural simulation, or CAE methods development with a focus on FEA-based approaches.
• Expertise with FEA tools such as Abaqus, ANSYS, OptiStruct, or similar platforms.
• Strong proficiency in fatigue analysis, nonlinear simulation, load case development, and structural durability.
• Experience developing or applying simulation methods to support engineering decision-making.
• Experience improving correlation between simulation results and physical test data.
• Experience with scripting and automation tools such as Python or TCL.
• Ability to work across global engineering teams and drive adoption of standardized processes and methodologies.
• Strong communication, interpersonal, and technical leadership skills.
• Familiarity with vehicle systems design and validation, particularly chassis, suspension, driveline, or structural systems.
• Knowledge of MBD tools and load development practices.

#LI-CS99

The starting pay range for Minnesota is $109,000 to $144,000 per year. Individual salaries and positioning within the range are determined through a wide variety of factors including but not limited to education, experience, knowledge, skills, and geography. While individual pay could fall anywhere in the range based on these factors, it is not common to start at the high end or top of the range.

To qualify for this position, former employees must be eligible for rehire, and current employees must be in good standing.

At Polaris we put our employees first, by offering a holistic approach to their health and financial wellbeing. Polaris is proud to offer competitive compensation, including a market-leading profit-sharing plan that is fundamental to our pay-for-performance culture. At Polaris, employees are owners of the company through company contributions to our Employee Stock Ownership Plan and discounted employee stock purchases plan. Employees receive a generous matchi