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
