Hybrid BI CAE Engineer

at Ford Motor Company

• Job title: BI CAE Engineer
• Job type: Full Time
• Experience level: Mid level, Senior
• Salary: Not specified
• Degree requirement: Bachelor's Degree
• Location requirements: Hybrid, Naucalpan de Juarez, Mexico

About the role

• Interior Systems CAE Engineer applying advanced CAE methods to optimize automotive interior components for occupant safety. Collaborating with teams to ensure product designs meet safety regulations.

Responsibilities

• Develop, execute, and validate detailed Finite Element Analysis (FEA) models for a wide range of interior components, including hard trim and overhead systems (e.g., headliners, sun visors, overhead consoles), with a strong emphasis on their performance during head impact events and in side airbag deployment.
• Utilize Computer-Aided Engineering (CAE) methods as primary tools to gain fundamental understanding of complex physical behaviors within interior systems, specifically focusing on injury criteria assessment and restraint system interaction (airbags).
• Provide data-driven insights and design recommendations to cross-functional teams, actively driving design improvements and optimizations for enhanced occupant protection and compliance with head impact and airbag deployment safety standards.
• Collaborate closely with design, engineering, and manufacturing teams to ensure designs meet all necessary internal quality standards and critical safety regulations related to head impact and airbag performance.
• Identify opportunities for cost-effective design solutions while maintaining or enhancing product performance and occupant safety attributes.
• Interpret simulation results, generate comprehensive reports, and present findings clearly and concisely to various stakeholders, specifically detailing head injury criteria (HIC), airbag interaction, and overall occupant protection performance.
• Contribute to the continuous improvement of CAE methodologies, tools, and processes, particularly for occupant safety analysis.
• Conduct root cause analysis for design failures or performance deficiencies identified through testing or field issues, providing data-driven recommendations for corrective actions, especially concerning occupant injury mechanisms, head impact failures, or airbag deployment anomalies.
• Clearly communicate complex technical concepts and simulation results to both technical and non-technical stakeholders, including insights on occupant safety performance and regulatory compliance.
• Participate in design reviews, peer reviews, and technical discussions, contributing expertise to drive consensus and informed decision-making, particularly for interior safety features and passive restraint systems.
• Contribute to the continuous improvement of CAE processes, best practices, and simulation toolchains to enhance efficiency and accuracy in head impact and airbag deployment simulations.

Requirements

• Engineering degree (Mechanical, Biomechanics, Mechatronics, Materials) or related disciplines with coursework in Finite Element Methods. MSc / Ph. D. degree preferred.
• Engineering Knowledge of Mechanical and Structural concepts: Linear / Nonlinear, Explicit and Implicit Dynamics (especially high-speed impact simulation), as well as Implicit and Explicit knowhow.
• Extensive experience with test correlation and validation of CAE models against physical crash test data (e.g., head impact tests, airbag deployment tests).
• Proficiency with industry-standard finite element software, especially explicit dynamic solvers (LS-Dyna).
• Experience with Team Center/Catia Environment.
• Strong understanding of material properties and their behavior under various loading conditions (elasto-plasticity, stress-strain etc.), especially rate-dependent material models relevant for crashworthiness.
• Familiarity with automotive industry standards and regulations, with deep knowledge of occupant protection regulations such as FMVSS 201 (Head Impact).
• Ability to analyze and interpret simulation results to provide actionable design recommendations, specifically regarding head injury criteria and airbag performance.
• Excellent problem-solving skills and a strong analytical mindset.
• Effective communication and interpersonal skills, with the ability to collaborate effectively with cross-functional teams.
• Familiarity with automotive interior systems (hard trim, overhead systems) is highly desirable, particularly their role in occupant protection and interaction with safety systems.
• Evidence of technical excellence as indicated by technical presentations and reports, particularly in the domain of head impact, airbag deployment, and occupant safety.
• Independent, self-motivated, goal oriented, highly organized and persistent.
• Able to work both independently and effectively with others.
• Passion to overcome challenges and keep learning.
• Be proactive for finding solutions to given issues.
• Fluent in English (oral and written).

Benefits

• Health insurance
• Retirement plans
• Paid time off
• Flexible work arrangements
• Professional development