Principal Product Engineer - FEA

Essential Functions/ Responsibilities

• Lead and perform complex finite element analysis (FEA) studies using industry standard tools (e.g., ANSYS Mechanical, LS-DYNA) for static, dynamic, shock, vibration, and thermo-mechanical loading across components and assemblies.
• Lead simulation-driven studies and analytical Design of Experiments (DOE) to quantify sensitivity to geometry, materials, process parameters, and boundary conditions.
• Multi-step, history-dependent mechanical and thermo-mechanical loading, including manufacturing and assembly load sequences, across components and assemblies.
• Analyze and predict fatigue, damage accumulation, and long-term reliability using physics-based metrics such as strain energy density, stress/strain range, and time and force dependent deformation behavior.
• Evaluate material behavior in metals, polymers, and composite materials to inform design and material selection.
• Develop, implement, and validate advanced material models including viscoelastic, creep, and stress relaxation behavior, particularly at elevated temperatures.
• Develop and correlate analytical models with physical test data to ensure accuracy and predictive capability.
• Provide technical mentorship for simulation engineers and lead standardization of FEA workflows, best practices, and analysis templates.
• Partner closely with cross-functional teams to ensure robust, manufacturable solutions that meet customer requirements.
• Communicate analytical findings effectively in design reviews, technical reports, and presentations to internal and external customers.

Required Experience

• 10+ years of experience conducting structural analysis using commercial FEA tools, with experience using advanced techniques such as shock, vibration, and coupled thermo-mechanical FEA.
• Deep understanding of mechanics, dynamic response, and material behavior (including creep, stress relaxation, and fatigue).
• Expert with commercial FEA tools and design software (e.g., ANSYS, Abaqus, Nastran, SolidWorks).
• Proven expertise in modeling complex mechanical systems, encompassing contact, anisotropic materials such as fiber-filled plastics, and nonlinear modeling.
• Experienced in shock, vibration, and reliability modeling and qualification of mechanical systems.
• Expertise in non-linear solution strategies, convergence control, contact stabilization, and solver selection for complex problems.
• Proven record of accomplishment interpreting complex simulation results and influencing engineering decisions and product design.
• Experience managing multiple projects simultaneously as priorities can change quickly.
• Excellent technical communication (written and verbal) and experience interfacing with customers, multidisciplinary engineering teams, and non-technical stakeholders.