Principal Structural & CAE Durability Engineer – Battery Systems
On-siteFremont, California, United States
Job Summary
Lead structural, fatigue, durability, and NVH CAE analysis for battery module and pack designs, including vibration fatigue, weld fatigue, and thermal cycling creep. Define and drive the structural/CAE analysis strategy, methods, and technology roadmap across battery engineering programs. Develop automation tools and standard work processes to improve modeling quality and efficiency. Apply optimization, DOE, and AI/ML techniques to guide design decisions. Partner with Design Release Engineers and cross-functional teams to ensure structural designs meet performance, safety, and reliability targets. Review and validate FEA models, structural calculations, and analysis reports for components including trays, cell tabs, and brackets. Lead root cause investigations of structural failures and field issues. Mentor and provide technical leadership to structural and CAE engineers across the team. Present analysis results, design recommendations, and program-level structural risk assessments to engineering and program leadership.
Required Qualifications
- PhD or MS in Mechanical Engineering, Structural Engineering, Solid Mechanics, or a related technical discipline
- 15+ years of experience in structural, fatigue, and durability CAE analysis, ideally within automotive, battery, or related industrial systems
- Expert-level proficiency in FEA and CAE tools such as ABAQUS, HyperWorks/OptiStruct, NASTRAN, LS-DYNA, ANSA, and nCode
- Strong background in fatigue, NVH, optimization/DOE, and multi-physics structural analysis
- Proven track record developing CAE automation tools and standard engineering work processes
- Experience with scripting/programming for CAE automation (Python, C/C++, Tcl/Tk, VBA, or similar)
- Demonstrated ability to define technical strategy, mentor engineers, and drive cross-functional collaboration
- Excellent written and verbal communication skills, with experience presenting to engineering and program leadership
Desired Qualifications
- PhD in Mechanical Engineering or Solid Mechanics
- Direct experience with battery module/pack structural design and durability analysis
- Experience applying AI/ML techniques to CAE modeling and design optimization
- Experience with Teamcenter/NX or similar PLM/CAD-integration environments
- Track record of patents, publications, or industry recognition in structural/CAE engineering
- Design for Six Sigma or related quality/process certification
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