Advanced Engineer - CAE Simulation

About the Role

The Advanced Engineer - CAE Simulation will lead and execute virtual validation and simulation activities to support development of safety‑critical restraint products. The role combines advanced finite element analysis, physical test correlation, and cross‑functional technical leadership to predict product performance, drive robust designs and ensure compliance with regulatory and customer requirements.

Key Responsibilities

CAE Simulation & Analysis

• Lead and perform finite element analyses (implicit and explicit) for component and system level simulations including crash, occupant protection and restraint system interactions.

• Develop, maintain and validate high‑fidelity FE models, material definitions and contact formulations suitable for safety‑critical products.

• Execute parametric studies, sensitivity analyses and design optimisation to support robust design recommendations.

• Produce clear, reproducible simulation procedures and modelling standards for use across the engineering team.

Test Correlation & Validation

• Correlate simulation results with component and system test data; identify and close gaps between CAE predictions and physical measurements.

• Support planning and interpretation of validation tests, provide pre‑test predictions and post‑test analysis reports.

• Document assumptions, boundary conditions and limitations of simulation studies; propose improvements to test and measurement plans.

Cross‑Functional Collaboration

• Work with design, prototyping, materials, manufacturing and quality teams to ensure simulation inputs reflect realistic designs and manufacturing conditions.

• Provide technical guidance to project teams, support design reviews and advise on DFMEA and design modifications driven by simulation findings.

• Coordinate with suppliers and external technical partners for material characterisation and specialised modelling tasks.

Process Improvement & Tools

• Improve CAE workflows, automate routine processes, and implement best practices for model verification and validation.

• Champion use of advanced simulation techniques (e.g. multi‑body dynamics co‑simulation, material nonlinearities, probabilistic approaches) where appropriate.

• Contribute to development of simulation training materials and mentor junior CAE engineers.

Deliverables

• Validated FE models and simulation packages supporting design decisions.

• Complete analysis reports, correlation evidence and documented assumptions for project archives.

• Actionable recommendations to improve product performance, safety and manufacturability based on simulation results.

• Automated scripts, standard modelling templates and documented CAE procedures.

• Timely delivery of simulation milestones to support project schedules and review gates.

Experience & Skills

• 4–8 years of experience in CAE, structural simulation or related engineering roles within the automotive or safety‑critical industries.

• Proven experience with explicit and implicit finite element solvers (e.g. LS‑DYNA, Abaqus/Explicit, Abaqus/Standard or equivalent).

• Strong skills in meshing, contact definition, non‑linear material modelling and model validation.

• Practical experience correlating CAE results with physical tests and interpreting measurement data.

• Proficiency in pre/post‑processing tools, scripting (Python, Tcl or similar) and data analysis.

• Familiarity with restraint systems (seat belts, airbags) or other occupant protection domains is