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Job Title: Finite Element Analysis Engineer (FEA)

Location: Milwaukee, WI

Job Type: Full-Time / Onsite

Position Overview

We are seeking a highly skilled Mechanical Modeling & Simulation Engineer specializing in the automotive and battery domain. In this role, you will perform advanced mechanical and thermal simulations to ensure the robustness, durability, and performance of next-generation lithium-ion battery systems. You will collaborate closely with battery system engineers, mechanical designers, and cross-functional engineering teams to validate design concepts and support product development from concept through production.

Key Responsibilities

Mechanical & Thermal Simulation

  • Perform finite element analysis (FEA) to evaluate structural integrity, mechanical robustness, and thermal performance of advanced energy storage systems.
  • Develop, refine, and execute simulations related to crash, crush, mechanical shock, vibration, and other real-world loading conditions.
  • Conduct thermal modeling of Li-ion battery systems, focusing on heat generation, dissipation, cooling strategies, and thermal runaway mitigation.

Design Collaboration & Review

  • Work closely with battery system engineers and mechanical design teams to validate design concepts and propose design improvements.
  • Interpret simulation results, provide detailed recommendations, and support design optimization.

Tools & Workflow

  • Build and manage high-quality CAE models using ANSA or HyperMesh for pre-processing and ABAQUS for simulation and post-processing.
  • Support CAD integration and review designs using SolidWorks or similar tools.

Documentation & Reporting

  • Prepare comprehensive engineering reports summarizing simulation methodology, assumptions, results, and conclusions.
  • Support engineering documentation for design reviews, validation checkpoints, safety assessments, and regulatory submissions.

Cross-Functional Collaboration

  • Partner with OE Automotive and Tier-1 suppliers on system-level simulations and component integration.
  • Participate in technical discussions, design reviews, and cross-functional project planning.

Required Qualifications

  • Master’s degree in Mechanical Engineering or a closely related field.
  • 5+ years of hands-on FEA experience , specifically with ANSA or HyperMesh and ABAQUS .
  • Strong knowledge of mechanical and thermal modeling techniques for complex mechanical systems.
  • Experience with automotive battery systems , energy storage components, or OE/Tier-1 assemblies.
  • 1+ years of CAD experience , preferably using SolidWorks.
  • Excellent communication skills and fluency in English.

Preferred Qualifications

  • Experience performing FEA for crash, crush, shock, and vibration analysis in line with automotive requirements.
  • Background in Li-ion battery mechanical design, enclosure design, cooling strategies, and thermal management .
  • Familiarity with automotive development processes such as APQP, DFMEA, and DVP&R.
  • Understanding of vehicle environment conditions, safety requirements, and battery regulatory standards (e.g., UN 38.3, UL 2580).