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Insight Global

Crash Simulation Engineer

Cambridge, MA, United States

From $80 USD / hour

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Job details

Pay: From $80 USD / hour
Experience: 3-7+ years of CAE, crashworthiness, vehicle structural analysis, or closely related nonlinear FEA experience
Posting language: English
Posted: Nov 2, 2026

Original job description

Required Skills & Experience

Bachelor's Degree in Mechanical Engineering, Automotive Engineering, Aerospace Engineering, or related engineering discipline
3-7+ years of CAE, crashworthiness, vehicle structural analysis, or closely related nonlinear FEA experience
Hands-on experience building, modifying, or preparing finite element vehicle/structural models using ANSA, HyperMesh, or a comparable preprocessing platform
Hands-on experience setting up or running crash/impact simulations using LS-DYNA, Radioss, or a comparable explicit dynamics solver
Experience analyzing at least one of the following: frontal impact, side impact, rear impact, roof/rollover, or BIW structural crash
Working knowledge of crash-model setup, including meshing, materials, contacts, connections, spot welds, bolts, adhesives, or similar joining methodologies
Ability to evaluate simulation outputs including structural deformation, intrusion, forces/loads, stresses, energy absorption, and component/material failure
Experience working with automotive or transportation structures such as BIW, rails, pillars, rockers, crossmembers, floor structures, crash boxes, bumpers, or structural joints
Ability to interpret crash results and recommend geometry, material, gauge/thickness, reinforcement, or connection changes
Comfortable working independently in a fully remote, workflow-driven environment with structured QA rather than traditional day-to-day management

Nice to Have Skills & Experience

Advanced experience with ANSA and/or HyperMesh
Advanced experience with LS-DYNA and/or Radioss
Full-vehicle crash model development or integration experience
Experience correlating CAE crash models with physical crash-test results
Experience with automotive Body-in-White (BIW), crashworthiness, occupant-compartment integrity, or structural optimization
Experience supporting an OEM, Tier 1, or Tier 2 automotive supplier, particularly advanced vehicle development programs
Experience troubleshooting model instability, contact behavior, material failure, connection behavior, or other nonlinear crash-simulation issues
Experience reviewing or validating simulation/engineering deliverables through formal quality assurance processes
Senior, Principal, Technical Lead, or Subject Matter Expert background
Previous participation in AI, engineering simulation, modeling, or engineering data-generation initiatives

Job Description

A cutting-edge engineering and AI-driven technology organization is rapidly expanding its U.S.-based engineering contractor network to support one of the largest ongoing engineering data initiatives in the market. Due to continued growth and consistent project volume, the team is seeking experienced Crash CAE / Crash Simulation Engineers with hands-on automotive crashworthiness and finite element modeling experience. This is a highly flexible, fully remote opportunity designed for experienced engineers looking for either full-time contract work or technical project work alongside a primary position. Engineers can select projects aligned with their expertise and availability, with workloads ranging from 20 to 40+ hours per week. Software licensing will be provided when necessary. Engineers will work on technical projects that replicate real-world vehicle crash and structural analysis scenarios, covering the process from FE model preparation through crash simulation, results analysis, and structural optimization. Projects may involve frontal impact, side impact, rear impact, roof/rollover, and Body-in-White (BIW) structural crashworthiness. Typical assignments may require engineers to prepare or modify vehicle FE models using ANSA or HyperMesh, including meshing, material assignment, connections, contacts, spot welds, adhesives, and other crash-model setup activities. Engineers will then set up and execute crash simulations using LS-DYNA or OpenRadioss (now called OpenCourant), analyze deformation and intrusion, loads/forces, stresses, energy absorption, and component or material failure, and determine why a structure is not performing as intended. Engineers may assess structures including rails, crash boxes, bumpers, pillars, rockers, roof rails, crossmembers, floor structures, firewalls, joints, sheet metal, and BIW assemblies. Based on simulation results, they will recommend changes to geometry, material, thickness, reinforcement, or joining strategies and rerun simulations to validate improvements. Rather than a traditional engineering organization with continuous management oversight, this environment uses structured workflows, automation, and self-service tools. Deliverables go through a robust quality-assurance process before becoming part of larger engineering initiatives. The organization is actively scaling its contributor network, creating opportunities for engineers to take on additional projects and increasingly complex technical work based on performance and expertise.

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