Sr. CAE Engineer – Durability Methods

Position Overview

You will provide technical leadership in the development and advancement of durability engineering methods to support next-generation off-road vehicle design. In this role, you will lead the application of FEA-driven simulation techniques to improve predictive accuracy, efficiency, and consistency across engineering teams. You will collaborate with global stakeholders to standardize processes, integrate physical test data, and influence early-stage product development decisions. You will also mentor engineers and promote adoption of best practices and scalable methodologies.

Key Responsibilities

• Lead the development, validation, and deployment of advanced durability methods using commercial CAE and FEA tools.
• Drive innovation in FEA-based simulation approaches, including fatigue analysis, nonlinear simulation, transient response, and complex joint modeling.
• Identify gaps in current CAE workflows and establish standardized processes to support global engineering consistency.
• Define and implement modeling guidelines, load case strategies, and post-processing procedures to improve scalability and repeatability.
• Develop and standardize load generation approaches, durability events, and virtual use cases.
• Collaborate with MBD and test teams to improve integration of loading data and enhance simulation fidelity.
• Improve correlation between simulation models and physical test results through validation and method refinement.
• Develop and implement automation strategies to streamline CAE workflows using scripting tools.
• Apply durability methodologies early in vehicle architecture development to influence design decisions and performance targets.
• Provide technical leadership, mentorship, and subject matter expertise to engineering teams.

Desired Competencies

• Technical / Functional Expertise: Apply the required technical or professional knowledge to perform your role effectively and stay current within your area of expertise.
• Critical Thinking: Analyze information objectively, evaluate options, and apply sound judgment to solve problems and make informed decisions.
• Leadership: Inspire, guide, and empower others to achieve their best by setting clear direction, fostering trust, and creating an environment where people feel supported, motivated, and accountable for delivering results.

Qualifications

• Bachelor’s degree in Mechanical Engineering or a related field.
• Minimum of 6 years of experience in durability analysis, structural simulation, or CAE methods development with a focus on FEA-based approaches.
• Expertise with FEA tools such as Abaqus, ANSYS, OptiStruct, or similar platforms.
• Strong proficiency in fatigue analysis, nonlinear simulation, load case development, and structural durability.
• Experience developing or applying simulation methods to support engineering decision-making.
• Experience improving correlation between simulation results and physical test data.
• Experience with scripting and automation tools such as Python or TCL.
• Able to work across global engineering teams and drive adoption of standardized processes and methodologies.
• Strong communication, interpersonal, and technical leadership skills.
• Familiarity with vehicle systems design and validation, particularly chassis, suspension, driveline, or structural systems.
• Knowledge of MBD tools and load development practices.

Pay

The starting pay range for Minnesota is $109,000 to $144,000 per year. Individual salaries and positioning within the range are determined through a wide variety of factors including but not limited to education, experience, knowledge, skills, and geography. While individual pay could fall anywhere in the range based on these factors, it is not common to start at the high end or top of the range.

Benefits

• Competitive compensation, including a market-leading profit-sharing plan that is fundamental to our pay-for-performance culture.
• Employee Stock Ownership Plan (ESOP) and discounted employee stock purchase plan.
• Generous matching contribution to 401(k).
• Financial wellness education and consultation.
• Comprehensive suite of benefits, including health, dental, and vision insurance, wellness programs, paid time off, gym & personal training reimbursement, life insurance and disability offerings.
• Polaris Foundation and Polaris Gives paid volunteer time off.

About Polaris

Polaris is the global leader in powersports, pioneering product breakthroughs and enriching experiences and services that invite people to discover the joy of being outdoors since our founding in 1954. Polaris' product lineup includes RANGER®, RZR® and POLARIS GENERAL™ side-by-side off-road vehicles; Sportsman® all-terrain off-road vehicles; military and commercial off-road vehicles; snowmobiles; Slingshot® moto-roadsters; Aixam quadricycles; Goupil electric vehicles; and pontoon and deck boats, including industry-leading BENNINGTON pontoons. Polaris enhances the riding experience with a robust portfolio of parts, garments, and accessories. Proudly headquartered in Minnesota, Polaris serves more than 100 countries across the globe.

EEO Statement

Polaris Inc. is an Equal Opportunity Employer and will make all employment-related decisions without regard to race, color, religion, creed, sex, sexual orientation, gender identity, national origin, age, disability, marital status, familial status, status with regard to public assistance, membership or activity in a local commission, protected veteran status, or any other status protected by applicable law. Applicants with a disability that are in need of an accommodation to complete the application process, or otherwise need assistance or an accommodation in the recruiting process, should contact Human Resources at 800-765-2747 or Talent.Acquisition@Polaris.com. To read more about employment discrimination protection under U.S. federal law, see: Know Your Rights: Workplace Discrimination is Illegal (eeoc.gov).