Structures and Chassis CAE Engineer - GM Defense

GM Defense; Warren (MI); Hybrid; USD 110,000 - 170,000; Full time

Job summary

GM Defense is seeking a Structures and Chassis CAE Engineer to apply finite element analysis to body, RESS, chassis, suspension, and steering structures. You will lead analyses of strength, stiffness, durability, and NVH, translating results into actionable design recommendations across Chassis Structure, Suspension, Steering, and Vehicle Dynamics teams.

The role requires a Bachelor’s degree in Mechanical, Aeronautical, Civil engineering or Physics with 5+ years in CAE, mentoring experience, and

Qualifications

• Bachelor’s degree in Mechanical Engineering, Aeronautical Engineering, Civil Engineering, Engineering, or Physics.
• 5+ years CAE/product design experience.
• Experience mentoring and leading teams.
• Familiarity with optimization, DOE, and CAE automation (Python/Tcl/Tk, AI/ML).
• Strong fundamentals in mechanics, physics, metallurgy, manufacturing, electronics, software, or control systems.
• Experience with CAE tools HyperWorks and/or ANSA; linear/nonlinear tools such as NASTRAN, OptiStruct, Abaqus, LS-DYNA, Adams.
• Experience with fatigue theory/tools (DesignLife, nCode).
• Strong communication and cross-team collaboration.
• U.S. Person or export authorization eligibility.

Responsibilities

• Perform CAE analyses to support vehicle program execution and technology development across structural systems.
• Support test development, root cause analysis, and issue resolution.
• Perform fatigue analysis and drive physical testing for chassis, suspension, RESS, and related components.
• Create, document, and archive analysis models and results.
• Present results and provide actionable recommendations for reviews and decisions.
• Participate in Chassis Structure, Suspension, Steering, Structures Product Development, Vehicle Dynamics, and NVH teams.
• Collaborate with design engineers to define system requirements and deliver technical solutions.
• Lead coordinated supplier CAE activities and support SR process.
• Develop, maintain, and update CAE plans and validation approaches.
• Provide technical leadership for advanced CAE methods and emerging tools.

Skills

CAE leadership

Mentoring

Python automation

DOE optimization

HyperWorks

ANSA

NASTRAN

Abaqus

LS-DYNA

Fatigue analysis

DesignLife

nCode

Communication

Education

Bachelor’s degree in Mechanical Engineering, Aeronautical Engineering, Civil Engineering, Engineering, or Physics

Master’s degree (preferred)

Tools

HyperWorks

ANSA

OptiStruct

Abaqus

LS-DYNA

Adams

Job description

The Role

The Structures and Chassis CAE Engineer supports GM Defense by applying finite element analysis tools and methods to the design and development of body structure, RESS structure, chassis structure, suspension, steering components, and other vehicle structures. This role leads analysis activities that assess strength, static and dynamic stiffness, durability, and noise and vibration performance, and translates results into clear design recommendations.

Job Description

The Role

The Structures and Chassis CAE Engineer supports GM Defense by applying finite element analysis tools and methods to the design and development of body structure, RESS structure, chassis structure, suspension, steering components, and other vehicle structures. This role leads analysis activities that assess strength, static and dynamic stiffness, durability, and noise and vibration performance, and translates results into clear design recommendations.

What You'll Do

• Perform CAE analyses to support vehicle program execution and technology development across structural systems.
• Support component and subsystem test development, root cause analysis, and issue resolution.
• Perform fatigue analysis and develop block cycles used to drive physical testing for chassis, suspension, RESS, and related structural components.
• Create, document, and archive analysis models and results.
• Present results and provide actionable recommendations to support virtual reviews and program decision-making.
• Participate in Chassis Structure, Suspension, Steering, Structures Product Development, Vehicle Dynamics, and Noise and Vibration Performance Integration teams.
• Work closely with design engineers to develop new components and subsystems, define system requirements, and deliver technical solutions for current and future programs.
• Lead coordinated supplier CAE activities and support the Statement of Requirements process.
• Develop, maintain, and update the CAE portions of analysis, development, and validation plans.
• Provide technical leadership for advanced technology development, contribute to new CAE methods and techniques, and stay current with emerging tools, trends, and competitive products.

Your Skills & Abilities (Required Qualifications)

• Bachelor’s degree in Mechanical Engineering, Aeronautical Engineering, Civil Engineering, Engineering, or Physics.
• 5+ years of related experience in product design and the CAE field.
• Experience mentoring others and providing technical leadership in a CAE-focused environment.
• Familiarity with optimization, DOE, and automation of CAE workflows using tools such as Python, Tcl/Tk, AI/ML or similar to enable efficiency, automate repetitive tasks, and drive rapid product development.
• Strong knowledge of engineering fundamentals relevant to the role, such as mechanics, physics, metallurgy, manufacturing methods, electronics, software, or control systems.
• Experience with CAE modeling tools such as HyperWorks and/or ANSA.
• Experience with linear and non-linear CAE analysis tools such as NASTRAN, OptiStruct, Abaqus, LS-DYNA, and/or Adams.
• Experience with structural fatigue theory, tools, and methods, including DesignLife and/or nCode.
• Strong written and verbal communication skills, sound analytical judgment, and the ability to solve complex, ambiguous problems while working effectively across teams.
• Candidate must either be a U.S. Person (U.S. citizen, U.S. permanent resident, asylee or refugee) or a non-U.S. Person who is eligible to obtain any required export control authorization.

What Will Give You A Competitive Edge (Preferred Qualifications)

• Master’s degree in Engineering
• Engineering design and release experience
• Optimization integration into product design and development
• Previous Defense industry experience

GM does not provide immigration-related sponsorship for this role. Do not apply for this role if you will need GM immigration sponsorship now or in the future. This includes direct company sponsorship, entry of GM as the immigration employer of record on a government form, and any work authorization requiring a written submission or other immigration support from the company (e.g., H1-B, OPT, STEM OPT, CPT, TN, J-1, etc). This role is categorized as hybrid. This means the selected candidate is expected to report to a specific location at least 3 times a week {or other frequency dictated by their manager}. The selected candidate will be required to travel <25% for this role. This job may be eligible for relocation benefits. This position requires the ability to legally operate a motor vehicle on a regular basis and successfully complete a Motor Vehicle Report review. The position is subject to export control restrictions and requires the successful candidate to be either a U.S. Person (U.S. citizen, U.S. permanent resident, asylee or refugee) or a non-U.S. Person who is eligible to obtain any required export control authorization.

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