Simulation Technical Expert

The individual will need to use and be comfortable operating in MATLAB, Dassault and Siemens signature flagship platforms to manage model configurations and maintain synchronized, traceable connectivity between CAD, PLM, and CAE/CFD tools, while building, correlating, and optimizing finite element models against standardized load cases and boundary conditions aligned with program checkpoints to drive performance, weight, and durability outcomes.

This role will also serve as the core simulation expert supporting the Mechatronic Systems team, acting as the go-to technical SME to develop and facilitate simulation needs and ensure mechatronic feature decisions are grounded in rigorous, well-validated simulation data. A core expectation of this position will be supporting the development and writing of advanced scripts and macros, that become reusable tools for global rollout of simulation processes across the broader organisation as the industry moves toward software-based verification.

In this position, you will:

• Simulation Technical Authority (Generative AI and MDAO): Act as the subject matter expert for adopting generative AI and multidisciplinary design optimization (MDAO) in simulation workflows. Move the team beyond manual use of commercial software toward automated, data-driven analysis and design exploration.

• Advanced CAE/CFD Analysis: Support System of Interest projects with subsystem- and vehicle-level analysis. Use Dassault 3DEXPERIENCE, Siemens platforms, Altair HyperWorks, Inspire/SimSolid, LS-DYNA, ADAMS and MATLAB to meet NVH, Vehicle Dynamics, and Durability KPIs, along with weight and performance targets.

• Proprietary Method and Algorithm Development: Develop proprietary algorithms and translation methods that convert data between disparate data sets and solvers. These methods must account for differences between static and dynamic load cases so that simulation results stay consistent across analysis conditions.

• Reusable Tools and Global Rollout: Support the development and writing of advanced scripts, macros, and automation pipelines. Turn them into standardized, reusable tools that enable global rollout of simulation processes across the organization as the industry moves toward software-based verification.

• Model Management and Traceability: Use MATLAB and the Dassault and Siemens flagship platforms to manage model configurations. Maintain synchronized, traceable connectivity between CAD, PLM, and CAE/CFD tools. Build, correlate, and optimize finite element models against standardized load cases and boundary conditions aligned with program checkpoints.

• System Optimization and Trade Studies: Optimize vehicle systems across cost, weight, and performance using tools such as ModeFRONTIER, 3DX Abaqus/Tosca, and Altair OptiStruct. Run MDO and sensitivity analyses to inform system selection.

• Mechatronics Simulation Expertise: Serve as the core simulation SME for the Mechatronic Systems team. Develop and facilitate their simulation needs so that mechatronic feature decisions rest on rigorous, well-validated data.

• Requirements Validation: Confirm that system requirements are applicable. Challenge requirements that lack clear legacy reasoning, and verify that system concepts are supported by simulation data.

• Virtual Modelling and Communication: Create virtual models on integrated platforms such as 3DX to bridge 3D CAD and CAE. Explain optimization concepts clearly to both CAD and CAE teams so turnaround is fast and needs few iterations.

• IP and Innovation: Identify and develop novel simulation methods, algorithms, and tools with patent potential. This supports Ford's competitive position in software-based verification.

• Bachelor's or Master's degree in Mechanical, Aerospace, Automotive Engineering, or related field (PhD a plus).
• Experience (15+ years) in CAE, FEA/FEM and simulation-driven design/testing within automotive or similar industry.
• Proven expertise in tools such as Dassault 3DX, Siemens platforms, Altair Hyperworks/Optistruct, LS-Dyna, ANSYS, MATLAB, ModeFRONTIER.
• Demonstrated experience developing custom scripts, macros or proprietary simulation methods.
• Strong communication skills to bridge technical and cross-functional teams.
• Experience contributing to patents or technical IP is a bonus.

Preferred Skills

• AI-driven analysis & automation: Experience applying AI/machine learning techniques to CAE/CFD workflows, simulation data processing, or predictive analytics for design optimization.
• Advanced scripting/programming: Proficiency in Python, MATLAB, or other scripting languages beyond basic tool operation, for developing reusable simulation tools and automation pipelines.
• Multidisciplinary Design Optimization (MDO) tools: Hands-on experience with ESTECO, Siemens & Dassault toolkits or similar optimization frameworks beyond foundational use.
• Mechatronics/electrified systems knowledge: Prior exposure to simulation of mechatronic, electrified, or software-defined vehicle features (e.g., actuators, sensors, control systems).
• Standards & certification knowledge: Familiarity with automotive industry standards for NVH, durability, or structural validation (e.g., SAE, ISO).
• Six Sigma / Lean methodologies: Exposure to structured problem-solving or continuous improvement frameworks applied to engineering processes.
• Certification: INCOSE/MIT (or similar) certified for systems engineering

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