iO Associates
Principal Engineer - FEA Analysis
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Job Description - Principal FEA Engineer
Overview
Our client is seeking an experienced Principal FEA Engineer to join a highly innovative engineering team developing advanced electromechanical systems for the automotive industry.
This is a senior technical position responsible for leading finite element analysis (FEA) activities throughout the product development lifecycle. Working closely with Mechanical Design, Systems, R&D and Validation teams, you will evaluate structural integrity, durability, fatigue performance and dynamic behaviour, helping to drive robust engineering solutions from concept through to production.
This role offers the opportunity to influence simulation methodologies, establish engineering standards and contribute to the continued growth of simulation capability within the business.
Whilst FEA is the primary focus, this is fundamentally a mechanical engineering role. The successful candidate will also support mechanical design activities, including CAD modelling, engineering drawings and design reviews, developing a comprehensive understanding of the products and engineering processes.
Key Responsibilities
Finite Element Analysis
- Develop and execute advanced finite element models using Ansys Mechanical and Workbench.
- Perform structural, thermal and fatigue simulations to support product development.
- Conduct:
- Linear and non-linear static analysis
- Modal analysis
- Transient dynamic analysis
- Collaborate with Mechanical Design Engineers to evaluate component geometry, material selection and loading conditions.
- Interpret simulation results and provide practical engineering recommendations to improve product performance, reliability and manufacturability.
- Produce detailed technical reports documenting modelling assumptions, methodologies, analysis results and recommendations.
- Support Design for Manufacturing (DFM) reviews using simulation data.
- Contribute to structured root cause investigations and 8D problem-solving activities through simulation-based analysis.
- Develop and maintain simulation standards, modelling templates and engineering best practices.
- Present technical findings to engineering teams, programme stakeholders, suppliers and customers.
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Mechanical Engineering Support
- Support mechanical design activities using SolidWorks.
- Produce and review 3D CAD models and 2D engineering drawings using industry-standard GD&T.
- Participate in engineering design reviews and cross-functional technical discussions.
- Collaborate with Mechanical, Systems, Manufacturing and Validation teams throughout the product development lifecycle.
- Provide technical leadership and mentoring in simulation best practices where appropriate.
Skills & Experience
Essential
- Bachelor's Degree in Mechanical Engineering or a related engineering discipline.
- Minimum of 7 years' experience performing finite element analysis using Ansys Mechanical.
- Strong experience in:
- Linear and non-linear structural analysis
- Modal analysis
- Transient dynamic analysis
- Excellent understanding of structural mechanics and material behaviour.
- Experience interpreting physical material test data, including non-linear material properties, and implementing these within simulation models.
- Strong analytical and problem-solving skills with the ability to translate simulation results into practical engineering recommendations.
- Excellent written and verbal communication skills with experience presenting technical findings to multidisciplinary engineering teams and external stakeholders.
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Desirable
- Experience with fatigue and durability analysis.
- Familiarity with CFD and thermal simulation tools.
- Experience within the automotive, motorsport or advanced engineering sectors.
- Knowledge of suspension, actuator or electromechanical system design.
- Experience supporting Design for Manufacturing (DFM) activities.
- MATLAB or equivalent scripting capability for engineering calculations and data analysis.
- Experience using SolidWorks for mechanical design.
- Working knowledge of Geometric Dimensioning and Tolerancing (GD&T).
- Master's Degree in Mechanical Engineering or a related discipline.
The Opportunity
This is an excellent opportunity to join a forward-thinking engineering organisation developing cutting-edge technology within the automotive sector. You'll work alongside highly experienced engineers on technically challenging projects, with the opportunity to influence engineering standards, shape simulation capability and contribute directly to the development of innovative products from concept through to production.
A competitive salary and comprehensive benefits package are offered, together with genuine opportunities for professional development within a collaborative and technically focused engineering environment.
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