LEAD SIMULATION ENGINEER

Job Overview

Work Location: Peenya, Bengaluru (100% On-site)

The Simulation Engineer (Staff Engineer/Manager) is responsible for leading advanced engineering simulations to support product design and development, with a focus on Finite Element Analysis (FEA), Computational Fluid Dynamics (CFD), and kinematic/dynamic analysis.

The role ensures that product designs are optimized for performance, reliability, and manufacturability through predictive simulation techniques. The engineer translates design requirements into simulation models, performs detailed analysis, and provides actionable insights to guide design decisions.

This role applies engineering fundamentals, numerical methods, and Design for Six Sigma (DFSS) principles to reduce development cycles, minimize physical prototyping, and improve product robustness, while ensuring compliance with regulatory and quality standards.

Job Responsibilities

• Develop and execute FEA, CFD, and multi-body dynamic simulations to validate and optimize product designs.
• Build accurate simulation models for structural, thermal, fluid flow, fatigue, vibration, and motion analysis.
• Perform kinematic and dynamic analysis of mechanisms and assemblies to ensure functional performance.
• Conduct design trade-off studies using simulation insights to improve performance, reliability, and cost.
• Support design verification and validation through correlation of simulation results with physical testing.
• Apply DFX principles (Design for Manufacturability, Reliability, Safety, Cost) using simulation-driven approaches.
• Identify and resolve complex engineering issues using simulation, analytical calculations, and first-principles methods.
• Ensure compliance with design control processes, regulatory requirements, and quality standards.
• Collaborate with cross-functional teams (Design, Manufacturing, Quality, Regulatory, and Supply Chain).
• Develop and standardize simulation methodologies, best practices, and documentation.

Job Qualifications

•    Bachelor’s or Master’s degree in Mechanical Engineering, Aerospace Engineering, or related field
•    8–12+ years of experience in simulation and product development
•    Proven experience in FEA, CFD, and multibody dynamics/kinematics analysis

Strong expertise in:
•    Finite Element Analysis (FEA): structural, thermal, nonlinear, fatigue, vibration
•    Computational Fluid Dynamics (CFD): flow, heat transfer, multiphase flows (preferred)
•    Kinematic & Dynamic Analysis: rigid body dynamics, motion simulation

Proficiency in simulation tools such as:
•    ANSYS (Mechanical, Fluent, CFX)
•    Abaqus / HyperWorks / Nastran / LS-DYNA
•    MSC Adams / Simcenter / RecurDyn (for dynamics)

Experience in:
•    Mesh generation and convergence studies
•    Material modeling and failure criteria
•    Solver setup, boundary conditions, and validation
•    Post-processing and interpretation of results
•    Experience integrating simulation with CAD tools (SolidWorks, Creo, NX)
•    Knowledge of plastic components, fluid systems, and mechanical assemblies
•    Ability to correlate simulation with experimental testing and validation data
•    Experience in automation/scripting (Python, MATLAB) is an added advantage
•    Strong documentation discipline in regulated environments
•    Ability to work independently and in cross-functional teams