CAE Crash and Safety Engineer (Full vehicle, Battery, LS-Dyna) Onsite - Michigan

Detroit Engineered Products is seeking a CAE Engineer specializing in full-vehicle crash simulation. The role uses LS-DYNA to predict crash performance, guide vehicle design decisions, and collaborate with design, testing, and manufacturing teams to improve crashworthiness and meet safety targets.

Responsibilities:

• Full Vehicle Simulation: Perform full vehicle crash simulations (Frontal, Side, Rear, and Pole impacts) using LS-DYNA to assess structural integrity and occupant safety
• Model Building & Assembly: Build, assemble, and debug complex full vehicle CAE models, including body-in-white (BIW), closures, chassis, and interior systems
• Correlation & Validation: Correlate simulation results with physical crash test data to ensure model accuracy and guide future modeling improvements
• Design Optimization: Propose design modifications to meet crash safety targets (e.g., intrusion limits, acceleration pulse, energy absorption) and collaborate with component teams to implement them
• Reporting: Prepare clear, concise technical reports and presentations for design reviews and management, highlighting risks and recommendations
• Process Improvement: Contribute to the development and automation of CAE workflows and standard operating procedures

Requirements:

• Bachelor's or Master's degree in Mechanical Engineering, Automotive Engineering, or a related field
• 3-5 years of hands-on experience in automotive crash simulation
• Expert proficiency in LS-DYNA (solver and post-processing)
• Experience with pre-processors (e.g., ANSA, HyperMesh) and post-processors (e.g., HyperView, Meta) is essential
• Strong understanding of explicit dynamics, material modeling (metals, plastics, foams), contact definitions, and nonlinear finite element analysis
• Familiarity with global crash safety regulations (FMVSS, ECE, NCAP, etc.)
• Experience with occupant safety simulations (Hybrid III / THOR dummies) using LS-DYNA
• Knowledge of structural optimization tools (e.g., OptiStruct, LS-OPT)
• Experience with scripting languages (Python, TCL/TK) for CAE automation
• Familiarity with pedestal testing and sub-system crash validation