Mechanical FEA Modeler

A globally leading technology company is looking for a skilled and detail-oriented Mechanical FEA (Finite Element Analysis) Modeler to join its engineering team. The ideal candidate will be responsible for all pre-processing steps, including geometry clean-up, material definitions, and meshing techniques, as well as occasionally running and interpreting FEA simulations using Abaqus software to support a variety of engineering projects. This position requires in-depth knowledge of finite element modeling, expert-level FEA modeling and meshing skills, and experience using NX CAD software for geometry preparation and cleanup. Strong analytical capabilities and the ability to translate real-world mechanical problems into accurate and effective simulation models are essential. Working-level skills in other preprocessors such as ANSA and Hypermesh are considered a strong plus. If you are passionate about simulation and engineering excellence, we invite you to apply and become part of this innovative global team!

Key Responsibilities
Utilize specialized equipment to build and test prototypes, systems, and components under electrical and mechanical stresses, supporting product development and validation efforts.
Design and develop customized testing equipment, fixtures, and protocols as needed to enable precise and reliable execution of mechanical and structural testing activities.
Perform detailed finite element modeling using Abaqus CAE software to simulate mechanical, structural, and thermal performance, ensuring accurate model setup and results interpretation.
Pre-process and post-process complex simulations, applying expert meshing techniques, element grouping, and relevant keywords through both manual methods and scripting for high-quality model generation.
Develop and implement material models based on experimental material testing data to ensure simulation accuracy.
Troubleshoot failed product and test samples by identifying root causes and proposing corrective actions or process improvements; perform system tear-downs as part of failure analysis.
Coordinate and lead root cause investigations involving internal and external stakeholders to resolve complex product and testing issues.
Troubleshoot and refine FEA models to improve convergence, reduce computational time, and enhance simulation fidelity.
Conduct regular safety checks and audits of testing equipment, ensuring all lab activities comply with safety protocols, regulatory standards, and good housekeeping practices.
Maintain current knowledge of industry best practices and advancements in FEA tools, simulation methodologies, and testing techniques.

Qualifications and Experience
Bachelor s or Master s degree in Mechanical Engineering, Aerospace Engineering, or a related field.
Minimum of 3 years of experience in finite element modeling using Abaqus CAE.
Hands-on experience with thermal measurement, strain gauge measurement, Instron measurement.
Proficiency in finite element modeling, with a strong grasp of model preparation and meshing, material models, boundary conditions, and load applications.
Experience in NX CAD software for importing and exporting model geometries.
Failure analysis experience (cross sections, Microscopy, SEM, FTIR, X-Ray, etc.)
Experience with fabrication machining (Mill, lathe, band saw, etc.) and 3D printing.
Strong analytical and problem-solving skills with keen attention to detail.
Excellent communication skills for reporting and collaborating with team members.

Preferred Skills
Background in mechanical design or structural analysis.
Experience with scripting in Python or other programming languages to automate tasks in Abaqus is a plus.
Familiarity with other FEA pre-processing and modeling tools (e.g., ANSA, Hypermesh, ICEPAK, COMSOL).
Experience with composite materials modeling or advanced material properties.
Certification in Abaqus or FEA-related training courses a plus.

Type: Contract
Duration: 12 months
Schedule: On-site (Cupertino, CA)
Pay range: $ 41.00 - $ 55.00 (DOE)