Sr. CAE Engineer - Exterior Trims & Mechanisms

Role details

As a Sr. CAE Engineer (RIV5), you will serve as the structural authority for Rivian’s Exterior Trims & Mechanisms—including Fascias, Front-End Structures, Headers, Spoilers, Claddings, Glass Mechanisms, and Side Mirrors etc.. You will lead subsystem-level virtual validation, drive dynamic non-linear simulations, and mentor cross-functional teams to deliver lightweight, highly durable, and crash-worthy exterior systems.

• Lead Subsystem CAE Analysis: Own structural, strength, and durability CAE for exterior trims and moving mechanisms. Execute advanced linear, non-linear static, explicit dynamic, and transient impact simulations.
• Master Critical Failure Modes: Predict performance across key load cases, including low-speed/pendulum bumper impacts, vehicle jacking/hoisting, step loads, operational abuse/slamming, and dynamic high-speed wind loading.
• Predict Polymer Durability: Apply advanced non-linear material models to evaluate polymers, composites, and structural foams under thermal cycles. Predict creep, environmental stress cracking, snap-fit insertion/extraction mechanics, and joint fatigue.
• Drive Cross-Functional Project Delivery: Lead 1–2 concurrent, high-intensity projects—guiding small teams (3–5 people) of Design, Material, and Supplier engineers (onsite and offshore) to deliver simulation results within fast-paced vehicle program timelines.
• Correlate & Validate: Model complex joining methods (adhesives, clips, snap-fits, rivets, bolts) and correlate virtual models against physical component and subsystem test results to maximize predictive accuracy.
• Champion First Principles & Best Practices: Apply core engineering fundamentals to explain failure modes and mentor Design Engineers on developing lightweight countermeasures that balance structural rigidity, styling, NVH, and manufacturing constraints. Document and standardize group-wide CAE technical specifications.

• Bachelors of Science in Mechanical Engineering (Masters/Phd Preferred)
• 5+ Years of Automotive CAE experience (Time spent in a relevant Master's Degree or Doctoral program may count towards work experience)
• Software Mastery: Proven expertise in LS-DYNA and ABAQUS for non-linear, transient dynamic, and structural simulations. Proficiency in pre/post-processors (ANSA, HyperWorks, META).
• Domain Expertise: Deep understanding of polymer/composite mechanics, plastic part design guidelines, and kinematic mechanism structural integrity (stress/deformation of moving joints).
• Regulatory & Durability Context: Working knowledge of bumper impact standards (FMVSS Part 581, ECE R42), pedestrian protection, and vehicle-level Due Care durability targets (jacking, operational abuse, thermal cycling).
• Communication & Leadership: Demonstrated capability to explain complex technical concepts, risk assessments, and countermeasures clearly to drive cross-functional alignment.

#### Preferred Qualifications:

• Experience of leading exterior trim and mechanism subsystems from early architectural concepts through physical test correlation.
• Experience with multidisciplinary design optimization tools (LS-OPT, OptiStruct) for lightweighting.