Crash & Safety CAE

Job Description Role: Vehicle Crash CAE Simulation & Evaluation Role Overview:- Responsible for preparing full vehicle and subsystem CAE models, performing crash and occupant safety simulations, interpreting results, and recommending countermeasures to improve safety performance. The role involves strong collaboration with design and testing teams to ensure correlation between CAE simulations and physical crash test results, ensuring compliance with safety regulations and NCAP protocols. Key Responsibilities:- Prepare full vehicle CAE models using HYPERMESH / ANSA / PRIMER including mesh discretization, assembly, constraints, and load setting for automotive subsystems and components. Perform system and full vehicle crash simulations using LS-Dyna. Develop vehicle body structures and aggregates for crash and occupant safety using CAE methods. Conduct model optimization and robustness studies using tools such as DiffCrash, ModeFrontier, and LS-OPT. Interpret crash simulation results in LS-PrePost / HyperView / HyperGraph, identify failure modes, and propose countermeasures through parameter studies. Prepare technical reports and present results to stakeholders including design and testing teams. Collaborate with testing teams to analyze failures, correlate CAE results with physical crash testing, and refine simulation methodologies. Competency Requirements Technical / Functional Skills Strong fundamentals in Strength of Materials and Theory of Elasticity / Plasticity. Good understanding of automotive body structures, sheet metal, and plastic part design. Knowledge of AIS Safety Regulations and NCAP protocols. Expertise in Finite Element Analysis (FEA) and experience in crash & occupant safety CAE (model building, system-level, and full vehicle simulations). Ability to debug CAE models in the LS-Dyna environment, interpret results, and perform post-processing. Experience in preparing comprehensive CAE analysis reports with recommendations and countermeasures. Exposure to physical testing and ability to represent test conditions in CAE (preferred). Behavioral Competencies Strong interpersonal, communication, and presentation skills. Achievement-oriented with attention to detail. Effective team player with good networking skills. Flexible and adaptable to dynamic project needs. Educational Qualification & Work Experience B.E / B.Tech / M.E / M.Tech in Mechanical / Automotive Engineering or related discipline. 3–7 years of experience in Automotive Crash CAE & Occupant Safety domain.