FEA Simulation Engineer

Company:

Job Description:

The FEA / Simulation Engineer develops and applies advanced engineering models to predict the structural performance, durability, and failure behavior of polymer, fiber-reinforced polymer, carbon composite, and metallic components.

The role converts customer and internal design requirements into defensible simulation plans, performs linear and nonlinear finite element analyses, correlates models with physical testing, and translates results into practical design and manufacturing recommendations.

The engineer will help expand simulation capability for anisotropic, short-fiber, discontinuous-fiber, including workflows that connect material behavior, fiber orientation, process history, and structural response.

The position also supports the evaluation and adoption of advanced engineering software, automation, artificial intelligence, machine learning, generative design, and related digital tools that improve analysis quality, speed, repeatability, and engineering decision-making.

Experience with injection molding simulation software such as Moldex3D or Autodesk Moldflow, or practical injection molding experience, is beneficial but not required. The successful candidate must be willing and able to learn Moldex3D, Moldflow, and other advanced simulation and AI-enabled engineering systems as business and technical needs evolve.

MAIN/KEY RESPONSIBILITIES AND ACCOUNTABILITIES:

Finite Element Analysis & Structural Simulation

• Plan, build, execute, and document finite element analyses for polymer, composite, and metallic components using customer-derived and internally defined load cases.

• Create linear and nonlinear static models, including material nonlinearity, geometric nonlinearity, large deformation, contact, friction, preload, and boundary-condition sensitivity as appropriate.

• Assess stress, strain, deformation, stiffness, stability, fatigue, life, and likely failure locations using analysis methods appropriate to the material, geometry, and application.

• Apply composite laminate theory, anisotropic material definitions, ply-level results, and suitable composite failure criteria to evaluate laminated structures.

• Develop methods for short-fiber and discontinuous-fiber structures, including mapped orientation and spatially varying material properties when supported by available process data.

• Evaluate mesh quality, convergence, assumptions, simplifications, and uncertainty; perform sensitivity studies and clearly identify model limitations.

• Optimize designs for weight, strength, life, manufacturability, dimensional performance, and other functional requirements.

Model Validation, Testing & Failure Analysis

• Define test requirements needed to establish loads, material inputs, boundary conditions, and validation data for engineering models.

• Partner with laboratory, design, manufacturing, and external testing resources to correlate analytical predictions with physical test results.

• Perform or support failure analysis to identify stress concentrations, load-path issues, local instabilities, contact problems, and material or design-related failure modes.

• Refine models based on test evidence and document correlation quality, residual uncertainty, and recommended next steps.

• Develop reusable modeling practices, material cards, validation approaches, and engineering standards that improve confidence and consistency across projects.

Design Support & Technical Recommendations

• Collaborate with design engineers to evaluate concepts, compare alternatives, and recommend geometry, material, tolerance, interface, and load-path improvements.

• Support conversion of metallic designs to polymer or composite solutions by assessing performance tradeoffs and identifying design changes needed for material substitution.

• Use simulation early in development to reduce technical risk, guide prototypes, focus physical testing, and accelerate design iterations.

• Provide clear, actionable recommendations rather than analysis results alone, connecting technical findings to customer requirements, manufacturability, cost, schedule, and commercialization risk.

• Participate in design reviews, project reviews, customer discussions, and technical problem-solving sessions.

Manufacturing Process Simulation & Injection Molding Knowledge

• Where qualified, apply process simulation or manufacturing knowledge to improve understanding of how molding conditions, fiber orientation, weld lines, shrinkage, warpage, residual stress, and other process effects may influence structural performance.

• Experience with Moldex3D, Autodesk Moldflow, or injection molding is beneficial but is not a minimum requirement for the position.

• Learn and become proficient with Moldex3D, Moldflow, or comparable process-simulation platforms when required, including workflows that transfer process results into structural analysis.

• Work with manufacturing and materials teams to understand actual process conditions and ensure simulation assumptions appropriately reflect how components are produced.

Advanced Software, AI & Generative Engineering

• Evaluate and adopt new engineering software and digital workflows that expand simulation capability or improve analysis speed, quality, traceability, and repeatability.

• Participate in the development of connected workflows between CAD, process simulation, material models, structural analysis, testing data, and engineering knowledge systems.

• Validate AI-generated or automated outputs using sound engineering judgment, documented checks, and applicable company requirements before results are used for technical decisions.

• Maintain a strong learning mindset and develop proficiency in unfamiliar advanced software systems as technology and business needs evolve.

Technical Documentation, Collaboration & Project Execution

• Prepare analysis plans, calculation packages, technical reports, design recommendations, and presentations that clearly communicate methods, assumptions, results, risks, and conclusions.

• Present complex technical findings to engineering, manufacturing, commercial, leadership, customer, and supplier audiences at an appropriate level of detail.

• Manage assigned analysis activities to agreed scope, schedule, and quality expectations while communicating risks and resource needs early.

• Work effectively across global and cross-functional teams and protect customer, company, and third-party confidential information and intellectual property.

• Contribute to capability roadmaps, software evaluations, licensing recommendations, training, templates, methods development, and continuous improvement of the simulation function.

Safety, Quality & Compliance

• Incorporate safety, quality, and applicable regulatory considerations into modeling, design recommendations, test planning, and technical reviews.

• Follow company procedures for engineering documentation, data management, software use, model review, and technical approval.

• Support safe laboratory and test activities and identify analysis-related risks that could affect personnel, equipment, product performance, or customer use.

5.0 SPECIAL FEATURES:

This role may support multiple sites, global teams, customer programs, laboratories, and manufacturing operations. Limited travel may be required based on project needs.

6.0 KNOWLEDGE/ EXPERIENCE/SKILLS:

7.0 EDUCATION

FEA Expertise: Strong working knowledge of finite element methods, model idealization, meshing, boundary conditions, loads, contacts, material models, convergence, verification, and interpretation of results.

Materials & Mechanics: Sound understanding of solid mechanics, strength of materials, failure theories, and the mechanical behavior of polymers, composites, and metals. Knowledge of laminate theory and composite failure criteria is required for composite-focused work.

Nonlinear Analysis: Ability to solve and troubleshoot nonlinear problems involving contact, friction, large deformation, nonlinear geometry, and nonlinear material behavior.

Validation & Engineering Judgment: Ability to define test needs, correlate models to data, recognize uncertainty, challenge assumptions, and distinguish numerical output from defensible engineering conclusions.

Digital Learning Agility: Demonstrated ability and willingness to learn advanced engineering systems, including process simulation, optimization, AI-assisted, machine-learning, generative design, and automation tools.

Communication & Collaboration: Ability to communicate technical results clearly in written reports and presentations and to work effectively with design, materials, testing, manufacturing, commercial, supplier, and customer teams.

Execution: Ability to prioritize work, manage multiple technical assignments, document decisions, and drive analysis tasks to timely completion.

Required

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Engineering Mechanics, or a closely related technical field.

• At least 3 years of applied FEA, modeling, and simulation experience; relevant graduate research may be considered as part of the overall experience.

• Proficiency with at least one commercial FEA platform capable of linear and nonlinear structural analysis, such as ANSYS Mechanical, Abaqus, or a comparable system.

• Experience building, troubleshooting, verifying, and documenting structural models and communicating results to technical stakeholders.

• Working knowledge of polymer, composite, or anisotropic material modeling and associated failure behavior.

• Ability and willingness to learn Moldex3D, Autodesk Moldflow, and other advanced simulation, AI-assisted, and generative engineering software as assigned.

• Demonstrated ability to work effectively in a collaborative, cross-functional environment and to prioritize and complete technical projects.

Preferred / Optional:

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

• Advanced experience modeling laminated, continuous-fiber, short-fiber, or discontinuous-fiber composite structures.

• Experience mapping manufacturing-process results, including fiber orientation or residual effects, into structural FEA.

• Familiarity with Moldex3D, Autodesk Moldflow, or comparable injection molding simulation software.

• Practical knowledge of injection molding, compression molding, extrusion, composite molding, or related polymer manufacturing processes.

• Experience with CAD tools such as SolidWorks, Siemens NX, or comparable platforms.

• Familiarity with optimization, AI/ML, generative design, reduced-order modeling, surrogate modeling, or engineering data analytics.

• Experience defining mechanical testing and correlating test results with analytical predictions.

• Experience supporting OEM customers or converting metallic components to polymer or composite designs.

NOTE: This job description is not intended, and should not be construed, to be an all-inclusive list of all responsibilities, skills, efforts, or working conditions associated with the job. While this job description is intended to be an accurate reflection of the job requirements, management reserves the right to modify, add or remove duties from jobs and to assign other duties as necessary.

The salary range for this position is $95,300-119,100. Factors such as scope and responsibilities of the position, candidate's work experience, education/training, job-related skills, int

ernal peer equity, as well as market and business considerations may influence base pay offered. This salary will be subject to a geographic adjustment (according to a specific city and state), if an authorization is granted to work outside of the location listed in this posting.

Mitsubishi Chemical Group (MCGC) and any of our subsidiaries do not accept unsolicited resumes from individual recruiters or third-party agencies. No fee will be paid to third parties who submit unsolicited candidates directly to our hiring managers or HR team. No placement fees will be paid to any firm unless specifically invited on the search by the MCGC Talent Acquisition team and such candidate was submitted to the MCGC Talent Acquisition Team via our Applicant Tracking System.

EEO Statement

All qualified applicants will receive consideration for employment without regard to race, color, sex, sexual orientation, gender identity, religion, national origin, disability, veteran status, or other legally protected status.

Applicants with disabilities may be entitled to a reasonable accommodation under the Americans with Disabilities Act and/or other applicable laws. If you require accommodation due to a disability at any time during the recruitment and/or assessment process, please contact Talent Acquisition.

Welcome

Thank you for your interest in working on our team!

About Us

At the MCC Group, our Purpose is to lead with innovative solutions to achieve KAITEKI, the well-being of people and the planet. Based on integrity and respect for others, we continuously engage in diverse co-creation and bold challenges, building trust with stakeholders while addressing social issues.

Shall we explore new possibilities with us by promoting value creation on a global scale and connecting a better future to the next generation?