Senior Additive Simulation Engineer, Structural Optimization

About the Team:

The Additive Technology team operates at the frontier of research and development, where creativity meets capability. This is an R&D-driven environment where problems are open-ended and solutions are yours to define. You'll work alongside welders, robotics engineers, data scientists, and systems engineers at the intersection of hardware and software, creating an end-to-end additive manufacturing platform that serves a wide variety of applications. From exploring new materials to unlocking faster print speeds, to designing complex, organic geometries that can't be built any other way, it's high-impact work that sets the foundation for the future of additive manufacturing.

About the Role:

• Develop, refine, and implement digital workflows for optimization-driven part design in additive manufacturing. This includes simulation, optimization, and manufacturability verification to ensure innovative and efficient solutions tailored to the unique capabilities of additive processes
• Collaborate with multidisciplinary teams to define design requirements and translate them into simulation-driven workflows supporting manufacturable geometries
• Perform structural analysis and optimization of metal components for additive manufacturing - ensuring efficient material usage and compliance with mechanical requirements
• Lead design exploration studies to generate and assess high-performance design alternatives and iteratively refine designs using advanced digital tools and collaborative workflows for optimal manufacturing readiness
• Leverage AI/machine learning for modeling and simulation workflow optimization: identify, develop and deploy algorithms to drive faster design and simulation cycles
• Document and present technical findings to engineers, managers, and stakeholders
• Evaluate new technologies and software relevant to metal AM simulation and structural optimization
• Work cross-functionally to implement cost reduction, methods and product improvements, and support prototype and production build activities

About You:

• Proficiency in finite element analysis (FEA), computational modeling, and optimization algorithms for structural evaluation and design automation
• Strong programming or scripting skills (e.g., Python, C#, Grasshopper, C/C++) for workflow automation and advanced simulation setup
• 5+ years of experience with modeling and simulation software (e.g., Siemens NX, Rhino, Abaqus, ANSYS, Nastran, OptiStruct, Tosca) with a proven track record in topology optimization and/or generative design for AM
• In-depth understanding of metal additive manufacturing processes and their impact on design constraints, material behavior, and post-processing needs
• Solid interpersonal skills and motivated self-starter who can manage personal workload and execution to tight schedule

Nice to haves but not required:

• Experience with multi-disciplinary or multi-physics optimization
• Experience interfacing with engineering, testing, and manufacturing groups to understand system designs and the associated constraints
• Excellent problem-solving and critical-thinking skills