Senior Mechanical Design Engineer - Simulations

About the role

Lead simulation efforts for next-generation Axon products from concept development through production.

Responsibilities

• Develop, validate, and maintain high-fidelity simulation models for mechanical components and complex system-level assemblies.
• Perform nonlinear static and dynamic analyses including impact, vibration, fatigue, drop, shock, and other mechanical loading conditions.
• Support simulation-driven product development by providing early analytical insight during concept development, prototyping, and product validation.
• Partner closely with Mechanical Design, Electrical Engineering, Product Management, Industrial Design, Manufacturing, Quality & Reliability, Failure Analysis, and Test Engineering to influence product architecture through simulation-driven design.
• Correlate simulation results with laboratory testing to improve model accuracy and increase confidence in design decisions.
• Identify design risks early and provide actionable engineering recommendations that improve durability, reliability, manufacturability, and overall product performance.
• Apply topology optimization, parametric studies, and analytical methods to develop lightweight, robust, and manufacturable designs.
• Troubleshoot complex mechanical reliability issues throughout the product development lifecycle.
• Present simulation results, technical findings, and design recommendations to cross-functional teams and engineering leadership.
• Continuously improve simulation methodologies, modeling standards, and best practices to accelerate product development.

Qualifications

• Bachelor's degree in mechanical engineering or related discipline; Master's degree preferred.
• Minimum 8 years of experience applying mechanical simulation and engineering analysis to product development for consumer electronics, aerospace, automotive, defense, robotics, public safety, or other high-reliability products.
• Advanced proficiency with simulation tools such as ANSYS, Abaqus, LS-DYNA, HyperMesh, or equivalent.
• Strong understanding of solid mechanics, nonlinear material behavior, fatigue, impact, vibration, numerical methods, and failure analysis.
• Demonstrated experience developing and validating simulation models through correlation with physical testing.
• Experience performing system-level simulations for complex electro-mechanical assemblies.
• Ability to translate simulation results into practical design recommendations that improve product performance, reliability, and manufacturability.
• Working knowledge of 3D CAD tools and mechanical design principles.
• Excellent analytical, communication, and presentation skills.
• Ability to balance competing technical constraints through simulation, testing, and engineering judgment.
• Collaborative mindset with experience working across multidisciplinary engineering teams in a fast-paced product development environment.

Preferred Qualifications

• Experience with ruggedization standards such as MIL-STD-810 or equivalent environmental and reliability test methods.
• Experience with topology optimization, parametric optimization, and design optimization techniques.
• Experience performing steady-state and transient thermal analysis using finite element methods.
• Experience simulating complex fluid phenomena including computational fluid dynamics (CFD), gas dynamics, aerodynamics, and thermal-fluid systems.
• Experience analyzing or resolving electromagnetic and Multiphysics simulation problems.
• Experience with Fluid-Structure Interaction (FSI), Immersed Computational Fluid Dynamics (ICFD), or coupled Multiphysics simulations.
• Familiarity with scripting and automation tools such as Python or MATLAB to streamline simulation workflows.

Benefits

• Competitive salary, bonus, RSUs, and 401(k) with employer match
• Discretionary paid time off
• Paid parental leave for all
• Medical, Dental, and Vision plans
• Fitness programs
• Emotional & Mental Wellness support
• Learning & Development programs
• Snacks in offices