Battery Pack Structural CAE Engineer

JOB TITLE: Battery Pack Structural CAE Engineer

LOCATION: Tustin, CA (Onsite)

SCHEDULE: Standard Working Hours

DURATION: 6-Month Contract

PAY: 75-80 USD per hour

Job Responsibilities:

In this role, you will support the analysis, development, and optimization of battery pack structures through advanced CAE simulations. You will work closely with design engineering teams to evaluate structural performance, improve durability, and validate battery system designs. Key responsibilities include:

• Leading battery system structural and dynamic analysis activities, including:
  • Modal analysis
  • Random vibration analysis
  • Shock analysis
  • Durability simulations
• Developing random vibration profiles for Pack-in-Fixture (PIF) testing.
• Designing and tuning PIF fixtures to accurately replicate vehicle response and damage.
• Performing durability analysis of battery systems using finite element analysis (FEA) tools.
• Collaborating with design engineers and suppliers to improve battery pack performance and optimize designs.

Essential Duties and Job Functions:

• Perform battery pack durability and structural analyses using Altair OptiStruct, ANSA, HyperView/META, and other CAE tools.
• Develop and validate Pack-in-Fixture (PIF) testing methodologies and vibration profiles.
• Analyze modal, random vibration, and shock responses of battery systems.
• Interpret simulation results and provide actionable design recommendations to engineering teams.
• Work with design engineers and suppliers to gather material properties, connection details, and CAE modeling information.
• Create and refine finite element models, including meshing and component connections.
• Support development and continuous improvement of durability analysis procedures and benchmark studies.
• Prepare formal engineering reports documenting analysis methods, results, and recommendations.
• Participate in cross-functional engineering discussions to improve battery system structural performance.

Knowledge & Skills:

• Strong understanding of structural mechanics, dynamics, and finite element analysis.
• Experience performing modal, random vibration, shock, and durability analyses.
• Proficiency with Altair OptiStruct (required).
• Experience with ANSA and HyperView/META.
• Experience with Abaqus or similar structural analysis software.
• Knowledge of automotive materials including metals, polymers, adhesives, conductors, and battery system components.
• Strong analytical and problem-solving skills.
• Excellent written and verbal communication skills with the ability to present technical findings.
• Ability to work effectively in a collaborative, cross-functional engineering environment.
• Experience preparing technical reports and presenting CAE results.

Education & Experience:

• Bachelor's degree in Mechanical Engineering or a related engineering discipline with 7+ years of relevant experience; or
• Master's degree with 2+ years of relevant experience; or
• PhD in Mechanical Engineering or a related field.
• Experience in automotive structural analysis, battery systems, or vehicle dynamics preferred.
• Experience with finite element modeling, meshing, and structural optimization.
• Background in battery pack structural analysis and durability testing is highly desirable.

Required Skill:

• Altair OptiStruct (Must Have)

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