About the Role

The Advanced Engineer - Materials CAE will lead and perform advanced simulation and virtual validation activities focused on material behaviour and its influence on safety‑critical products. The role combines constitutive material modelling, finite element analysis, physical test correlation and technical leadership to predict performance, support robust designs and ensure compliance with regulatory and customer requirements.

Key Responsibilities

Materials Modelling & Characterisation

• Develop, implement and maintain advanced material models (rate, temperature and strain‑rate dependent, damage and failure) for polymers, metals, composites and textile reinforcements used in restraint and occupant protection systems.

• Define and document material test programmes; liaise with test labs to obtain tensile, compression, shear, fracture and cyclic data necessary for model calibration.

• Perform inverse modelling and parameter optimisation to derive robust material model parameters from experimental data.

CAE Simulation & Analysis

• Integrate advanced material definitions into component and system finite element models (implicit and explicit) and assess their influence on structural and occupant protection performance.

• Conduct sensitivity analyses, parametric studies and probabilistic assessments to quantify the effect of material variability on safety and durability.

• Prepare reproducible modelling procedures and material libraries for use across projects and teams.

Test Correlation & Validation

• Correlate material‑aware CAE predictions with component and system test results; identify discrepancies and refine models to improve predictive accuracy.

• Provide pre‑test predictions, post‑test analyses and clear documentation of material assumptions, boundary conditions and limitations.

• Recommend additional test methods or measurement techniques to close modelling gaps and improve confidence in simulation outputs.

Cross‑Functional Collaboration

• Work closely with design, materials, manufacturing and quality teams to ensure material selections and process conditions are correctly represented in simulations.

• Advise project teams on material‑driven design choices, DFMEA inputs and mitigation measures derived from CAE findings.

• Engage with suppliers and external laboratories for specialised material characterisation and model validation activities.

Process Improvement & Tools

• Drive improvements in material modelling workflows, automate calibration routines and develop standardised material libraries and templates.

• Promote advanced techniques such as multi‑scale modelling, viscoelastic/viscoplastic formulations and probabilistic approaches where appropriate.

• Mentor junior engineers in material characterisation, constitutive modelling and CAE best practice; contribute to training materials.

Deliverables

• Validated material models and documented material libraries suitable for use in design and safety analyses.

• Complete simulation packages and correlation evidence linking material behaviour to component and system performance.

• Clear analysis reports, assumptions logs and recommended actions to mitigate material‑related risks.

• Automated calibration scripts, standard modelling templates and documented procedures for material characterisation and implementation.

• Timely delivery of material modelling milestones to support project schedules and review gates.

Experience & Skills

• 4–8 years of experience in materials CAE, constitutive modelling or related roles within automotive, aerospace or other safety‑critical industries.

• Proven experience with finite element solvers and material modelling tools (e.g. Abaqus, LS‑DYNA, Ansys or equivalent) and implementing custom material models.

• Strong knowledge of constitutive models for metals, polymers, composites and textiles including damage and failure criteria.

• Practical experience correlating material models with experimental data and interpreting measurement results.

• Proficiency in pre/post‑processing tools, scripting for model calibration and automation (Python, Matlab or similar) and data analysis.

• Familiarity with restraint systems (seat belts, airbags), occupant protection or related safety domains is desirable.

• Degree in Mechanical Engineering, Materials Science, Applied Mechanics or a related discipline; postgraduate qualification is advantageous.