Finite Element Analysis Engineer

2 weeks ago

Milwaukee WI, United States Global Connect Technologies Full time

Job Title: Finite Element Analysis Engineer (FEA) Location: Milwaukee, WI Job Type: Full-Time / Onsite Position Overview We are seeking a highly skilled Mechanical Modeling & Simulation Engineer specializing in the automotive and battery domain. In this role, you will perform advanced mechanical and thermal simulations to ensure the robustness, durability, and performance of next-generation lithium-ion battery systems. You will collaborate closely with battery system engineers, mechanical designers, and cross-functional engineering teams to validate design concepts and support product development from concept through production. Key Responsibilities Mechanical & Thermal Simulation Perform finite element analysis (FEA) to evaluate structural integrity, mechanical robustness, and thermal performance of advanced energy storage systems. Develop, refine, and execute simulations related to crash, crush, mechanical shock, vibration, and other real-world loading conditions. Conduct thermal modeling of Li-ion battery systems, focusing on heat generation, dissipation, cooling strategies, and thermal runaway mitigation. Design Collaboration & Review Work closely with battery system engineers and mechanical design teams to validate design concepts and propose design improvements. Interpret simulation results, provide detailed recommendations, and support design optimization. Tools & Workflow Build and manage high-quality CAE models using ANSA or HyperMesh for pre-processing and ABAQUS for simulation and post-processing. Support CAD integration and review designs using SolidWorks or similar tools. Documentation & Reporting Prepare comprehensive engineering reports summarizing simulation methodology, assumptions, results, and conclusions. Support engineering documentation for design reviews, validation checkpoints, safety assessments, and regulatory submissions. Cross-Functional Collaboration Partner with OE Automotive and Tier-1 suppliers on system-level simulations and component integration. Participate in technical discussions, design reviews, and cross-functional project planning. Required Qualifications Master’s degree in Mechanical Engineering or a closely related field. 5+ years of hands-on FEA experience , specifically with ANSA or HyperMesh and ABAQUS . Strong knowledge of mechanical and thermal modeling techniques for complex mechanical systems. Experience with automotive battery systems , energy storage components, or OE/Tier-1 assemblies. 1+ years of CAD experience , preferably using SolidWorks. Excellent communication skills and fluency in English. Preferred Qualifications Experience performing FEA for crash, crush, shock, and vibration analysis in line with automotive requirements. Background in Li-ion battery mechanical design, enclosure design, cooling strategies, and thermal management . Familiarity with automotive development processes such as APQP, DFMEA, and DVP&R. Understanding of vehicle environment conditions, safety requirements, and battery regulatory standards (e.g., UN 38.3, UL 2580).

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