CAE Crash Simulation Engineer (ANSA, PAM-CRASH, LS-DYNA)

1. Position Details

• Position: CAE Crash Simulation Engineer
• Experience: 5–8 years
• Location: Kuala Lumpur, Malaysia (Onsite Placement) / India upon return
• Employment Type: Full-Time
• Number of Positions: 10
• Domain: Automotive Crash Simulation and Structural CAE
• Customer Interview: Yes

2. About the Role

3. Key Responsibilities

• Perform automotive crash simulations and structural impact analysis using LS-DYNA and/or PAM-CRASH.
• Prepare, clean, mesh, and validate finite element models using ANSA.
• Develop and optimise crash simulation models, including component, subsystem, and full-vehicle assemblies, as required by the project.
• Conduct crashworthiness assessments for relevant crash scenarios, including frontal, side, rear, and other impact cases.
• Evaluate simulation results, including stress, strain, deformation, intrusion, energy absorption, and acceleration responses.
• Identify structural failure modes and recommend design improvements to enhance crash performance and occupant safety.
• Support model setup, solver deck preparation, boundary conditions, contact definitions, material properties, and load-case configurations.
• Perform model quality checks and troubleshoot simulation errors, convergence issues, and unexpected results.
• Correlate simulation results with available physical test data and support model validation activities.
• Prepare simulation reports, technical documentation, and presentations highlighting key findings and design recommendations.
• Collaborate with design, CAE, testing, and project engineering teams to resolve structural performance issues.
• Participate in technical reviews and project discussions.
• Ensure simulation activities meet project requirements, quality standards, and agreed delivery timelines.

4. Required Skills & Qualifications

• Bachelor's or Master's degree in Mechanical Engineering, Automotive Engineering, or a related discipline.
• 5–8 years of relevant experience in automotive CAE, crash simulation, and structural analysis.
• Practical experience with at least one major crash simulation solver: PAM-CRASH (preferred) or LS-DYNA.
• Strong hands-on experience with ANSA for finite element model preparation, meshing, and quality checks.
• Good understanding of finite element analysis (FEA), explicit dynamic analysis, and impact mechanics.
• Knowledge of automotive crashworthiness principles, vehicle structural behaviour, and energy absorption mechanisms.
• Experience with material modelling, contact definitions, boundary conditions, and solver setup.
• Ability to interpret simulation results and recommend engineering design improvements.
• Knowledge of post-processing tools is an added advantage.
• Understanding of model quality criteria, simulation validation, and correlation with physical test results.
• Strong analytical, problem-solving, and technical reporting skills.
• Good communication and collaboration skills to work effectively with an international project team.
• Willingness to relocate to Kuala Lumpur, Malaysia.

5. Why Join Us?

• Opportunity to contribute to automotive crashworthiness and vehicle safety engineering projects.
• Direct collaboration with an international automotive engineering team.
• Hands-on exposure to industry-standard CAE tools and crash simulation methodologies.
• Opportunity to extend the assignment or explore longer-term engineering support opportunities, subject to project requirements.