Technical Specialist - Elastomer CAE

Ford • Dearborn, MI

17h • Hybrid

About The Position

We made history and now we work to transform the future – for our customers, our communities and our families. You'll see your work on the road every day, helping people move freely and pursue their dreams. At Ford, you can build more than vehicles. Come build what matters.
Product Development uses design thinking & user experience methods to deliver breakthrough products and services that delight our customers. We bring innovative, exciting, and sustainable ideas to life. We have opportunities around the world for you to contribute to advancements in autonomy, electrification, smart mobility technologies, and more!
As the Technical Expert for Elastomer CAE, you will be the primary authority on the simulation of suspension bushings, subframe mounts, jounce bumpers, and steering isolators. You will lead the development of high-fidelity models that capture the non-linear, frequency-dependent, and amplitude-dependent behavior of rubber components.

Requirements

• Master’s Degree in Mechanical Engineering, Material Science, Polymer Mechanics, Aerospace Engineering, or a related field.
• 10+ years of experience in non-linear Finite Element Analysis (FEA).
• At least 6 years of Proven experience as elastomer CAE engineer or similar role.
• Deep understanding of elastomer CAE models and analysis techniques.
• Expert-level proficiency in Abaqus/Standard, Abaqus/Explicit, and Marc.
• Experience with fatigue software such as Endurica or FE-safe/rubber.
• Deep understanding of continuum mechanics and the mathematical foundations of non-linear deformation.

Nice To Haves

• PhD in Mechanical Engineering, Material Science, Polymer Mechanics, Aerospace Engineering, or a related field.
• Hyperelastic Theory: Ability to determine the appropriate strain energy density function based on experimental data.
• Dynamic Analysis: Experience in predicting dynamic stiffness and loss angle for bushings across varying frequency ranges.
• Thermal Effects: Understanding the impact of temperature on elastomer properties (Arrhenius behavior and heat build-up).
• Manufacturing Integration: Knowledge of the injection molding process and how "knit lines" or "grain direction" affect the final structural integrity of the part.
• Optimization: Proficiency in using Tosca or Isight for the shape optimization of voids or inserts to achieve specific directional stiffness rates. Proficiency in leveraging parametric elastomer CAD models for optimizing geometry for durability and NVH performance.

Responsibilities

• Lead the CAE strategy for integrating complex elastomer models into full-vehicle and sub-system chassis simulations.
• Develop and implement advanced material models, including hyper-elasticity (e.g., Ogden, Yeoh, Mooney-Rivlin), viscoelasticity (time and frequency domain), and Mullins effect.
• Create CAE Test Methods to design and validate supplier rubber bush components.
• Develop block cycles for accelerated fatigue testing.
• Lead the correlation of CAE results with physical lab testing (MTS rigs, DMA, and Shore hardness testing) to ensure simulation accuracy.
• Work closely with the Materials Engineering team to define testing protocols and with the NVH/vehicle Dynamics teams to optimize dynamic stiffness and damping.
• Implement and refine fatigue life prediction methodologies for rubber components, considering multi-axial loading and environmental factors.
• Drive the implementation of elastomer fatigue life prediction to ensure chassis components meet durability requirements for the life of vehicle without degradation.
• Assist in root cause analysis of field issues and implementing corrective actions.
• Establish workflows to translate high-fidelity FEA bushing results into linearized or non-linear reduced-order models for use in MBD models.
• Develop standardized workflows and scripts (Python/Abaqus CAE) to streamline the analysis of complex assemblies.
• Lead the technical development of junior CAE engineers, conducting deep-dive reviews and internal training sessions.
• Stay at the forefront of industry trends, including the use of sustainable/recycled elastomers and AI/ML applications in material characterization.

Benefits

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level