Job Description

Job Title: Occupational Safety CAE Engineer

Location: Irvine, CA

Onsite

Contract

Position Summary:

We are seeking an experienced and detail-oriented Occupational Safety CAE Engineer to lead virtual analysis and development of vehicle systems focused on occupant protection and workplace safety. The role requires advanced simulation capabilities in crash and ergonomics assessments, combined with deep knowledge of regulatory safety standards. The ideal candidate will play a key role in supporting vehicle programs by ensuring safety performance targets are met using CAE tools.

Key Responsibilities:

CAE Simulation & Analysis:

• Lead finite element simulations related to occupational safety, including front, side, rear crash, rollover, and whiplash scenarios.
• Conduct occupant injury prediction and restraint system analysis using tools like LS-DYNA, PAM-CRASH, or Abaqus.
• Evaluate structural crashworthiness and perform detailed analysis on components like seats, airbags, seatbelts, IP, and floor panels.
• Perform ergonomics and ingress/egress studies for driver and passenger safety using RAMSIS or similar tools.

Safety & Compliance:

• Ensure virtual designs comply with global safety regulations and consumer test protocols (e.g., FMVSS, ECE R14/17/25, NCAPs).
• Provide CAE support for proving regulatory compliance and program sign-off.
• Guide the design team in achieving optimal safety performance with lightweight and cost-effective structures.

Technical Leadership & Collaboration:

• Lead virtual safety design reviews and contribute to the definition of occupant packaging, restraint layout, and vehicle architecture.
• Work closely with cross-functional teams including crash test, hardware safety, biomechanics, seating, and body structures.
• Guide junior engineers and provide technical mentorship in CAE methodology and interpretation.

Reporting & Documentation:

• Document simulation procedures, results, and recommendations with traceable data and clear justifications.
• Present CAE results to internal teams, suppliers, and management with actionable insights for design improvement.
• Manage correlation studies between CAE and physical tests for model validation.

Required Qualifications:

• Bachelor’s or Master’s degree in Mechanical Engineering, Automotive Engineering, Biomechanics, or related field.
• 7+ years of experience in CAE-based safety analysis for automotive or commercial vehicle applications.
• Proficient in crash and safety simulation tools such as LS-DYNA, ANSA, Animator/Post, or similar.
• Solid understanding of vehicle occupant safety systems and biomechanics.
• Familiarity with regulatory and NCAP safety protocols (US, EU, China, etc.).

Preferred Qualifications:

• Experience with crash dummy modeling (e.g., Hybrid III, THOR, WorldSID) and injury metrics (e.g., HIC, Nij, chest deflection).
• Hands-on experience with physical testing or correlation of test and simulation data.
• Knowledge of Human Body Models (HBM), virtual dummy positioning tools, and coupling of thermal or fatigue CAE is a plus.
• Exposure to vehicle development lifecycle and familiarity with PLM systems.

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