Occupant Safety CAE Engineer

Job Title: Occupational Safety CAE Engineer Location: Plymouth, MI Onsite 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.