Project Engineer, CAE

CAE Project Engineer This is a hybrid position and requires onsite work at our Towson, MD Design Center  3 days per week.   Towson, MD, United States    Come build something that matters. It takes great people to achieve greatness. People with a sense of purpose and integrity. People with a relentless pursuit of excellence. People who care about making things better For Those Who Make The World™. Sound like you? Join our top-notch team of more than 50,000 diverse and high-performing professionals globally who are making their mark on some of the world’s most beloved brands, including DEWALT®, BLACK+DECKER®, CRAFTSMAN®, STANLEY®, CUB CADET®, and HUSTLER®.

Overview:  We are seeking an experienced CAE Project Engineer to join our Towson CAE team. In this individual contributor role, you will collaborate with cross-functional teams to utilize advanced simulation tools for analyzing and optimizing the durability and performance of our power tool products. Your expertise in CAE simulation technologies will be crucial in driving product development and ensuring high-quality outcomes.

Utilize CAE simulation technologies to support product development. Translate product design requirements into simulation project specifications, employing appropriate simulation techniques to ensure quality and performance. Conduct structural analysis using FEA tools in areas including linear static, non-linear static, transient dynamic, noise and vibration, material damage, fatigue life prediction, fluid structure interaction, design optimization, co-simulation, and multi-physics simulation. Verify simulation results with theoretical methods and test data. Analyze simulation results to inform sound design and business decisions in complex technical situations. Collaborate with cross-functional teams to achieve optimal product development solutions. Study the fundamental physics behind products using CAE and other analytical tools. Develop advanced methods and processes to enhance simulation capability and efficiency. Manage and deliver multiple projects with increasing technical complexity. Work effectively in a fast-paced team environment, communicating efficiently with cross-functional teams.

Master’s degree or higher in Mechanical Engineering, Engineering Mechanics, Material Science, Physics, or a related field. 6+ years of hands-on experience in FEA modeling within the consumer products industry. Proficiency in major FEA tools (e.g., ANSYS, LS-DYNA, ABAQUS, Hypermesh, or equivalent). Strong knowledge of FEA theory, material failure criteria, solid mechanics, and fracture mechanics. Experience in one or more of the following areas: advanced dynamic impacts, advanced material modeling, fatigue calculation, vibration modeling, wear phenomena modeling, programming, and design optimization. Experience with 3D CAD & PLM systems. Ability to verify simulation results using sound engineering principles. Understanding of mass production manufacturing methods, such as die casting, plastic injection molding, and forging. Proven ability to work independently and collaboratively within a cross-functional team environment. Ability to manage multiple projects and flexible to adjust project priorities based on current business needs. Strong analytical and problem-solving skills, with a keen attention to detail. Ability to generate and evaluate creative ideas. Excellent technical documentation skills and strong written and verbal communication abilities. Preferred Skillsets: 10+ years of hands-on experience in applying FEA within the consumer products industry. Experience in FEA modeling specifically for power tools. Expertise in structural FEA tools, particularly ANSYS Mechanical and ANSYS DYNA. Advanced material modeling expertise for metals, plastics, rubber, concrete, wood, etc., including material damage and removal modeling, fatigue life prediction, and noise and vibration prediction.