Senior Manufacturing Engineer - Manufacturing Process Analysis

About This Role

This senior role focuses on developing physics-based analysis methods to understand, predict, and improve critical manufacturing processes for automotive propulsion systems. It suits a highly technical, research-oriented engineer who thrives in environments with ambiguity, enjoys continuous learning, and is motivated by developing innovative solutions to complex, open-ended problems.

Responsibilities

• Partner with manufacturing, plant, product design, materials, and process engineering teams to define complex technical problems and analysis objectives
• Conduct FEA, CFD, thermal, structural, and multiphysics analyses to identify root causes and develop practical solutions
• Investigate heat treatment, material phase transformation, thermal gradients, residual stress, distortion, ductility, and other material and process behaviors
• Apply simulation to manufacturing processes such as casting, machining, assembly, welding, and fluid flow
• Develop analysis approaches independently, including selection of appropriate physics, assumptions, boundary conditions, material models, and solution methods
• Perform research and literature reviews to support model development and technical recommendations
• Create and improve analysis methods and workflows using tools such as Abaqus, Altair HyperWorks, STAR-CCM+, Dante, NX CAD, and Python
• Automate preprocessing, solver execution, post-processing, and reporting where appropriate
• Correlate simulation results with test, inspection, plant, experimental, or production data
• Post-process and interpret results, prepare technical presentations, and communicate conclusions to internal customers and leadership
• Provide technical guidance, train others, and mentor or coordinate the work of a small group of engineers as needed

Requirements

• Bachelor's degree in Mechanical Engineering, Materials Engineering, Manufacturing Engineering, or a related engineering discipline
• 3+ years of professional experience applying engineering simulation methods, including FEA, CFD, or related modeling tools, with 5+ years preferred
• Experience developing, interpreting, validating, or applying engineering models to solve technical problems
• Strong analytical and problem-solving skills
• Ability to work independently in environments with incomplete information and evolving requirements
• Strong technical communication and collaboration skills

Nice to have:

• Master's degree or PhD in Mechanical Engineering, Materials Engineering, Manufacturing Engineering, or related discipline
• Experience with heat treatment simulation, metallurgy, phase transformation, distortion prediction, or material behavior analysis