BI CAE Engineer

An Interior Systems CAE Engineer is a specialized professional responsible for applying advanced Computer-Aided Engineering (CAE) methods to analyze and optimize automotive interior components, with a particular focus on occupant protection during crash events. This role involves developing and utilizing Finite Element Analysis (FEA) models to understand complex physical phenomena and predict the performance of parts like cockpit and trim, seat structure, seat plastics, and overhead systems, specifically in relation to head impact protection and airbag deployment scenarios. The engineer's primary objective is to leverage these simulation tools to provide fundamental insights, advance product designs, perform optimizations, and offer design recommendations. This ensures that interior system designs are robust, manufacturable, cost-effective, and meet all necessary internal quality and critical safety regulations (FMVSS, ECE Regulations) and customer requirements through close collaboration with cross-functional teams. This position offers a unique opportunity to directly influence product development from concept to production, working within a collaborative, cross-functional environment, and directly contributing to vehicle occupant safety.

• Engineering degree (Mechanical, Biomechanics, Mechatronics, Materials) or related disciplines with coursework in Finite Element Methods. MSc / Ph. D. degree preferred.
• Engineering Knowledge of Mechanical and Structural concepts: Linear / Nonlinear, Explicit and Implicit Dynamics (especially high-speed impact simulation), as well as Implicit and Explicit knowhow.
• Extensive experience with test correlation and validation of CAE models against physical crash test data (e.g., head impact tests, airbag deployment tests).
• Proficiency with industry-standard finite element software, especially explicit dynamic solvers (LS-Dyna).
• Experience with Team Center/Catia Environment.
• Strong understanding of material properties and their behavior under various loading conditions (elasto-plasticity, stress-strain etc.), especially rate-dependent material models relevant for crashworthiness.
• Familiarity with automotive industry standards and regulations, with deep knowledge of occupant protection regulations such as FMVSS 201 (Head Impact).
• Ability to analyze and interpret simulation results to provide actionable design recommendations, specifically regarding head injury criteria and airbag performance.
• Excellent problem-solving skills and a strong analytical mindset.
• Effective communication and interpersonal skills, with the ability to collaborate effectively with cross-functional teams.
• Familiarity with automotive interior systems (hard trim, overhead systems) is highly desirable, particularly their role in occupant protection and interaction with safety systems.
• Evidence of technical excellence as indicated by technical presentations and reports, particularly in the domain of head impact, airbag deployment, and occupant safety.
• Independent, self-motivated, goal oriented, highly organized and persistent.
• Able to work both independently and effectively with others.
• Passion to overcome challenges and keep learning.
• Be proactive for finding solutions to given issues.

• Fluent in English (oral and written).

• Develop, execute, and validate detailed Finite Element Analysis (FEA) models for a wide range of interior components, including hard trim and overhead systems (e.g., headliners, sun visors, overhead consoles), with a strong emphasis on their performance during head impact events and in side airbag deployment.

• Utilize Computer-Aided Engineering (CAE) methods as primary tools to gain fundamental understanding of complex physical behaviors within interior systems, specifically focusing on injury criteria assessment and restraint system interaction (airbags).
• Provide data-driven insights and design recommendations to cross-functional teams, actively driving design improvements and optimizations for enhanced occupant protection and compliance with head impact and airbag deployment safety standards.
• Collaborate closely with design, engineering, and manufacturing teams to ensure designs meet all necessary internal quality standards and critical safety regulations related to head impact and airbag performance.
• Identify opportunities for cost-effective design solutions while maintaining or enhancing product performance and occupant safety attributes.
• Interpret simulation results, generate comprehensive reports, and present findings clearly and concisely to various stakeholders, specifically detailing head injury criteria (HIC), airbag interaction, and overall occupant protection performance.
• Contribute to the continuous improvement of CAE methodologies, tools, and processes, particularly for occupant safety analysis.
• Conduct root cause analysis for design failures or performance deficiencies identified through testing or field issues, providing data-driven recommendations for corrective actions, especially concerning occupant injury mechanisms, head impact failures, or airbag deployment anomalies.
• Clearly communicate complex technical concepts and simulation results to both technical and non-technical stakeholders, including insights on occupant safety performance and regulatory compliance.
• Participate in design reviews, peer reviews, and technical discussions, contributing expertise to drive consensus and informed decision-making, particularly for interior safety features and passive restraint systems.
• Contribute to the continuous improvement of CAE processes, best practices, and simulation toolchains to enhance efficiency and accuracy in head impact and airbag deployment simulations.