Product Development Simulation Engineer

Job Summary

The Product Development Simulation Engineer will support the structural analysis activities of the Product Development Engineering Department. The position involves the use of Finite Element Analysis (FEA) software, classical calculations, and other techniques to evaluate the structural integrity of plastic injection‑molded components, assemblies, or systems by analyzing stresses, strains, and deformations under various loading conditions. The engineer will collaborate with others, communicate effectively, and maintain Hellermann Tyton’s Quality and EMS certifications by supporting all corporate policies, procedures, work instructions, and required documentation.

Perform FEA Simulations and Analysis:

• Create detailed 3D finite element models using CAD data, defining material properties, and applying boundary conditions to predict how products behave under various conditions, optimizing designs for intended performance before production.
• Identify potential failure points, stresses, deformations, and areas for improvement or optimization.
• Work with various engineering teams to design, model, simulate, and implement innovative solutions.
• Collaborate with stakeholders to understand project requirements and define simulation objectives.

Static and dynamic analysis:

• Perform static stress analysis, modal analysis, and transient dynamic simulations to assess structural behavior under various loading scenarios.

Nonlinear analysis:

• Use advanced non‑linear FEA techniques for complex loading conditions such as contact interactions, plasticity, and large deformations.

Verification, Validation, and Correlation:

• Ensure the accuracy and reliability of simulation models through testing and data analysis.
• Develop and implement test plans to validate model accuracy and improve model fidelity.

Design optimization:

• Identify potential design flaws and suggest improvements to optimize structural performance and minimize material usage.
• Use simulation results to guide design decisions and optimize performance, reliability, and durability.

Material Characterization and Material Models:

• Support efforts to define material properties and models that best simulate material behavior.

Documentation and Report Communication:

• Prepare reports and presentations summarizing findings and recommendations.
• Maintain accurate and complete documentation of all FEA analyses performed and results obtained.
• Effectively communicate across the organization to a diverse range of technical and non‑technical team members.

Process Improvement and

Collaboration:

• Continuously improve simulation processes and methodologies to enhance efficiency and accuracy.
• Conduct literature reviews to identify topics of interest for internal research and development.
• Work with other engineers and designers to incorporate FEA analysis into the product development process.

• Bachelor’s degree in Mechanical Engineering, Materials Engineering, or a related field.
• Proficiency in FEA software (e.g., ANSYS, Abaqus, Nastran) and a strong understanding of FEA principles and methods.
• 5 years of experience in a related design field with 2+ years of relevant experience in polymer‑based modeling of mechanical performance.
• Strong understanding of structural mechanics principles (stress analysis, beam theory, plate theory), engineering polymers, and associated manufacturing processes.
• Experience with CAD software (e.g., Solid Works, Catia, Creo) for model manipulation and creation.
• Excellent analytical and problem‑solving skills.
• Ability to work independently and collaborate with cross‑functional teams.
• Strong technical communication skills and capacity for communicating complex ideas to diverse audiences.
• Self‑motivated, organized, efficient, process‑oriented, with a strong work ethic.
• Ability to travel domestically and internationally.

• Master’s Degree preferred with 2 years of professional experience using commercial software to develop multiphysics models.
• Advanced degree (Master’s) in mechanical engineering with an emphasis in Modeling & Simulation or similar field of study.
• Experience developing predictive…