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Senior Mechanical Engineer (Finite Element Analysis Focus)

About the position

Battelle delivers when others can’t. We conduct research and development, manage national laboratories, design and manufacture products and deliver critical services for our clients—whether they are a multi-national corporation, a small start-up or a government agency. We recognize and appreciate the value and contributions of individuals from a wide range of backgrounds and experiences and welcome all qualified individuals to apply. The Mechanical Engineer will support advanced engineering analysis and research efforts focused on complex mechanical systems and assemblies, with a strong emphasis on finite element modeling and simulation. This role is responsible for performing high-fidelity structural and multiphysics analyses to support critical programs, including those involving large-scale, highly complex models and novel engineering challenges. The successful candidate will also support a cross-disciplinary project team analyzing and interpreting fastener and joint allowables data per Metallic Material Properties and Development Standardization (MMPDS) guidelines for inclusion into the MMPDS Handbook. The position requires deep expertise in finite element analysis (FEA), including development of custom scripts and subroutines, and the ability to work at the forefront of modeling capabilities—often collaborating with software developers and technical experts to solve problems beyond standard tool applications. This role will play a key part in sustaining and advancing advanced FEA capabilities supporting high-visibility and mission-critical programs.

Responsibilities

Perform advanced finite element modeling and analysis (FEA) on complex mechanical assemblies and systems
Develop and implement custom scripts and user subroutines for simulation
Conduct structural, fracture mechanics, and multiphysics analyses of metal, non-metal, and composite components and assemblies.
Analyze material, fastener, and joint allowables data per MMPDS guidelines.
Write, review, and present MMPDS Agenda Items at bi-annual meetings.
Collaborate with software vendors (Abaqus, ANSYS) on advanced modeling challenges
Support critical programs requiring high-confidence analyses
Compile and evaluate design and test data and prepare technical recommendations
Prepare reports and present findings to stakeholders
Participate in technical conferences, peer review panels, industry committee meetings, and other forums to increase company visibility.
Travel ~10%
Lead or support technical projects and ensure quality and schedule adherence
Mentor junior engineers and guide analysis methodology

Requirements

Bachelor’s degree or higher in a relevant technical field
Five plus years of experience in a safety focused industry such as aerospace, nuclear, or power generation with experience in structual design
Demonstrated experience in advanced FEA on complex systems
Strong background in structural analysis or fracture mechanics
Experience with scripting or custom simulation tools
Ability to work independently on complex analysis problems
Technical Writing and Presenting
Strong communication skills
Experience mentoring junior staff
Willingness and ability to learn new modeling software

Nice-to-haves

Experience with large-scale, high-complexity models
Proficiency in Abaqus and ANSYS
Experience supporting government or defense programs
Background in nuclear, aerospace, marine, and/or automotive industries
Subject Matter Expertise in at least two of the following: Fatigue, Damage Tolderance, Fastener Analysis, Joint llowables Development, Machine Design
Multiphysics modeling experience
Active or ability to obtain a security clearance

Benefits