CAE Durability Engineer

About this role

We’re ALTEN Technology USA, an engineering company helping clients bring groundbreaking ideas to life—from advancing space exploration and life-saving medical devices to building autonomous electric vehicles. With 3,000+ experts across North America, we partner with leading companies in aerospace, medical devices, robotics, automotive, commercial vehicles, EVs, rail, and more.

As part of the global ALTEN Group—57,000+ engineers in 30 countries—we deliver across the entire product development cycle, from consulting to full project outsourcing.

When you join ALTEN Technology USA, you’ll collaborate on some of the world’s toughest engineering challenges, supported by mentorship, career growth opportunities, and comprehensive benefits. We take pride in fostering a culture where employees feel valued, supported, and inspired to grow.

Overview :

• Bachelor's degree in Mechanical Engineering or Aerospace Engineering required. Minimum 6+ years of CAE experience with strong expertise in durability, fatigue, and structural analysis of automotive systems.

• Experience with Abaqus, ANSA, HyperWorks, META, and nCode is required.

• This role is responsible for developing and executing finite element simulations to evaluate vehicle durability and structural performance.

• The engineer will partner with design and validation teams to identify risks, recommend countermeasures, and support the development of robust vehicle systems.

Key Responsibilities : FE Model Development & Quality

• Construct high-quality finite element meshes and models for body, chassis, and vehicle subsystems

• Develop complex vehicle-level CAE models supporting durability and structural performance evaluations

• Ensure model quality, accuracy, and correlation with engineering requirements

• Utilize ANSA, HyperWorks, and other pre-processing tools for model construction and preparation

Durability & Structural Analysis

• Perform nonlinear finite element analyses using Abaqus to evaluate component and system durability

• Conduct strength and fatigue assessments on structural vehicle systems

• Analyze simulation results and identify potential performance concerns

• Provide engineering recommendations to improve component durability and robustness

Fatigue Life Assessment

• Perform fatigue life evaluations using nCode post-processing tools

• Interpret fatigue and durability results to predict product life performance

• Identify critical fatigue locations and potential failure risks

• Support engineering decision-making with data-driven durability assessments

Engineering Validation & Testing Support

• Support test validation activities to improve simulation accuracy and correlation

• Participate in investigations related to physical testing and durability requirements

• Compare test and CAE results to improve model quality and predictive capabilities

• Collaborate with validation teams to ensure alignment between simulation and testing objectives

Research & Method Development

• Lead research efforts focused on enhancing CAE durability methodologies

• Develop and implement improvements to existing simulation processes and workflows

• Investigate new tools, techniques, and best practices for durability analysis

• Drive continuous improvement initiatives across CAE processes and standards

Problem Resolution & Countermeasure Development

• Investigate durability concerns identified through simulation activities

• Develop effective countermeasure plans to address structural performance issues

• Partner closely with design engineering teams to implement design improvements

• Support issue resolution throughout the product development cycle

Technical Communication & Cross-Functional Collaboration

• Prepare and deliver clear technical reports, presentations, and engineering recommendations

• Communicate simulation findings to engineering leadership and project teams

• Work closely with design, testing, and validation organizations

• Provide technical leadership and support for durability-related engineering activities

Profile :

• Strong analytical engineer with deep interest in vehicle durability and structural performance

• Passionate about solving complex engineering challenges using CAE methodologies

• Comfortable working on highly technical vehicle development programs

• Strong ownership mindset with the ability to independently drive analysis activities

• Excellent problem-solving and root cause investigation capabilities

• Effective communicator capable of presenting complex technical findings to diverse audiences

• Collaborative team player who works well across engineering functions

• Continuous improvement mindset with interest in advancing CAE methods and processes

Must Have :

• Bachelor's degree in Mechanical Engineering or Aerospace Engineering

• 6+ years of CAE analysis experience within automotive or related industries

• Minimum 4 years of experience with ANSA, META, HyperWorks, Abaqus, or similar CAE software

• Strong finite element modeling and meshing experience

• Experience conducting nonlinear finite element analysis using Abaqus

• Experience performing fatigue and durability assessments

• Working knowledge of nCode fatigue post-processing tools

• Strong understanding of vehicle structures, body systems, and chassis components

• Experience creating and presenting technical reports and engineering recommendations

• Ability to work cross-functionally with design, testing, and validation teams

Good to Have :

• Master's degree in Mechanical Engineering, Aerospace Engineering, or related field

• Automotive OEM or Tier 1 supplier experience

• Vehicle durability development experience

• Test correlation and CAE validation experience

• Advanced fatigue and fracture mechanics knowledge

• Experience developing or improving CAE methodologies and best practices

• Exposure to full vehicle durability simulation activities

• Leadership experience supporting technical proje

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