Senior Crash CAE Engineer — BiW Simulation & Dataset Lead, Durban

About the Role

A senior-level role for someone who can own crash simulation methodology end-to-end. You'll define the simulation strategy, validate FE models against known test data, and set the quality bar for a large synthetic crash dataset powering machine learning surrogate models.

What You'll Do

Own FE model development and validation strategy for parametric BiW crash simulations Lead conversion and adaptation of existing LS-DYNA models (CCSA Camry-class vehicles) into OpenRadioss-compatible decks via ANSA Take a parametrically designed BiW and automate the setup in ANSA Define simulation protocols across multiple load cases: frontal rigid wall, MPDB, small overlap oblique, side pole, and roof crush Establish spot weld and structural connection modeling standards across the full BiW assembly (pattern, failure criteria, element formulation) Ensure energy balance, mass scaling, and hourglassing are within acceptable bounds across every run Build or supervise automated META post-processing pipelines to extract structured, ML-ready outputs Act as technical bridge between the simulation team and the ML engineering team

Requirements

Deep expertise in vehicle crash CAE, structural impact, or explicit dynamics simulation Deep expertise in LS-DYNA and/or OpenRadioss / AltairRadioss — fluent in at least one, willing to bridge both Expert-level ANSA pre-processing: connections, mesh morphing, load case setup, model validation Expert-level META post-processing: automated results extraction, force-displacement curves, intrusion measurements Proven track record validating FE models against physical crash test data Deep understanding of vehicle crash physics: crush zone behavior, load path management, energy absorption, occupant cell integrity

Nice to Have

Direct experience generating simulation datasets for ML or surrogate modeling applications Python scripting for pre/post-processing automation Understanding of how parametric CAD variation affects simulation setup Experience with NHTSA, IIHS, or Euro NCAP testing protocols Prior work with NCAC / CCSA open-source vehicle FE models