Simulation Engineer (FEA/DEM/CFD), MFG Engineering – Job Description

 

Job Summary
 
We are seeking a highly skilled Simulation Engineer to join our engineering and R&D organization. This role focuses on the development, execution, and integration of particle-based simulations with structural, mechanical, and thermal multiphysics simulations to support advanced manufacturing and materials development.

 

You will work closely with cross-functional teams—including materials, process engineering, QC, and manufacturing—to model complex physical phenomena, validate against experimental data, and deliver actionable insights to accelerate product development.

Key Responsibilities 

  • Particle Simulation Development: Build and optimize discrete element method (DEM) simulations for particle systems, including powder flow, compaction, mixing, and segregation. Model particle-to-particle and particle-to-surface interactions with high fidelity. Develop simulation workflows to capture particle geometry, size distributions, and material properties from experimental characterization.
  • Multiphysics Integration: Couple particle simulations with structural, mechanical, and thermal finite element analysis (FEA) or computational fluid dynamics (CFD) models. Simulate how particle behavior influences macro-scale mechanical integrity, heat transfer, and thermal stresses. Support multiphysics workflows linking discrete particle results into continuum simulations for tool design and process optimization.
  • Validation & Data Integration: Collaborate with metrology/QC teams to align simulation parameters with experimental data from real processes and equipment. Incorporate sensor, timeseries, and process parameter data into simulation boundary conditions. Analyze d

  

Minimum Qualifications

 

  • Bachelor’s, Master’s, or PhD in Mechanical Engineering, Materials Science, Chemical Engineering, Computational Physics, or related field.
  • 3+ years of experience in particle simulations using tools such as Ansys Rocky, Altair EDEM, or comparable DEM software.
  • Experience with structural, mechanical, and thermal simulation tools (e.g., Ansys Mechanical, OptiStruct, COMSOL).
  • Demonstrated ability to integrate DEM with FEA/CFD multiphysics environments.
  • Strong understanding of contact mechanics, particle dynamics, and thermomechanical coupling.
  • Proficiency in scripting/simulation automation (Python, MATLAB, etc.).
  • Familiarity with CAD integration, mesh generation, and solver setup.
  • Experience with HPC or GPU-accelerated simulations is a plus.
  • Knowledge of manufacturing workflows involving powders, compaction, and thermomechanical processing is strongly preferred.
  • Excellent problem-solving and analytical skills.
  • Strong communication skills to present results to technical and non-technical stakeholders.
  • Ability to work in a fast-paced, interdisciplinary environment.

 

Preferred Skills

 

  • Coupling simulation results to digital twin systems.
  • Familiarity with manufacturing and QC workflows in materials processing.
  • Knowledge of materials used in electrode and battery manufacturing.

 

What we offer

 

  • Collaborate with a cross-disciplinary team of innovators, engineers, and scientists.
  • A chance to work on high-impact problems with real-world applications.
  • Apply AI not in theory, but in mission-critical manufacturing systems.
  • A culture that values curiosity, initiative, and getting your hands dirty.
  • Influence the future of manufacturing AI from the ground up.