Senior Automotive Occupant Safety CAE Engineer

About the Role

This position is focused on the development, validation, and optimization of virtual occupant protection systems for frontal and side impact crash performance. The role involves developing and maintaining high-fidelity LS-Dyna occupant safety models, evaluating occupant injury performance, and optimizing restraint systems and interior components to achieve regulatory, consumer information, and internal safety targets. The engineer will collaborate closely with Safety Structures, Interior Systems, Chassis, Testing, Design Release Engineers (DREs), and suppliers to ensure occupant protection performance is achieved throughout vehicle development. This position requires deep expertise in automotive occupant safety, restraint systems tuning, crash simulation methodologies, and North American safety regulations, along with the ability to drive cross-functional technical decisions throughout the product development lifecycle.

Responsibilities

• Occupant Safety CAE Development
  • Develop and maintain occupant protection CAE models using LS-Dyna
  • Support frontal and side impact simulation activities throughout vehicle development
  • Ensure CAE models accurately reflect the latest vehicle design and CAD releases
  • Maintain correlation between component-level and system-level CAE models
• Occupant Performance Analysis
  • Assess occupant injury performance across all required crash configurations
  • Evaluate vehicle performance against internal safety targets, FMVSS requirements, US-NCAP, and IIHS protocols
  • Analyze simulation results and identify opportunities for performance improvements
  • Develop recommendations to improve occupant protection outcomes
• Restraint System Optimization
  • Optimize airbags, seatbelts, steering columns, seats, instrument panels, and interior trim systems
  • Tune restraint systems to achieve regulatory compliance and top consumer ratings
  • Develop occupant protection strategies across multiple crash scenarios
  • Support development of occupant safety scorecards and performance targets
• Cross-Functional Engineering Collaboration
  • Work closely with DREs and suppliers to ensure component models are properly correlated
  • Support integration of restraint and interior component models into complete vehicle simulations
  • Collaborate with Safety Structures teams when vehicle structural performance impacts occupant safety targets
  • Partner with Interior, Chassis, and other engineering organizations to resolve performance gaps
• Physical Test Correlation & Validation
  • Support crash test planning and execution activities
  • Collaborate with testing teams to ensure simulation assumptions align with physical testing results
  • Participate in test reviews and correlation activities
  • Refine simulation models based on physical test data
• Program Delivery & Technical Leadership
  • Support occupant safety development throughout all program phases through SOP
  • Maintain quality and accuracy of occupant protection models
  • Provide technical guidance regarding occupant safety performance and simulation methodology
  • Support resolution of complex safety and crashworthiness challenges

Qualifications

• Bachelor's degree in Mechanical Engineering, Automotive Engineering, Biomechanics, or related discipline
• Minimum 8-10 years of experience in Occupant Safety Engineering, Crashworthiness, or Automotive CAE Safety Analysis
• Strong LS-Dyna experience for occupant protection and crash simulation
• Experience with occupant safety development for frontal and side impact events
• Experience tuning and optimizing: airbags, seat belts, seats, steering columns, instrument panels, and interior trim components
• Strong knowledge of FMVSS 208, FMVSS 214, US-NCAP, and IIHS
• Experience developing and maintaining occupant safety CAE models
• Experience correlating CAE and physical crash test results
• Experience working with cross-functional engineering teams and suppliers
• Strong analytical and problem-solving abilities

Preferred Skills

• Humanetics CAE dummy model experience
• Experience with Primer
• Experience with ANSA / META
• Experience with HyperWorks
• Experience with LS-PrePost
• Experience supporting vehicle launches from development through SOP
• OEM or Tier 1 automotive experience
• Experience working in startup or fast-paced vehicle development environments
• Knowledge of global safety regulations beyond North America