Senior CAE Engineer – Structural Analysis, E-Axle Driveline

AVL

Senior CAE Engineer at AVL analyzing structural validation of e-axle and driveline components. Collaborating with engineering teams and reporting findings through structured documentation.

Posted 6/18/2026full-timeSala Al Jadida • 🇲🇦 MoroccoSeniorWebsite

Tech Stack

Tools & technologies

Python

About the role

Key responsibilities & impact

CAE Analysis & Simulation Develop, prepare and execute finite element models for the structural validation of e-axle, driveline and transmission components.
Perform nonlinear static, contact and fatigue analyses on complex multi-body assemblies.
Independently set up and validate: Contact interactions across multiple component interfaces, including detailed tooth-to-tooth contact.
Interference and press-fit conditions.
Bolt pretension/preload modelling and bolted-joint safety assessments.
Multi-Point Constraints (MPCs) and complete connectivity definitions.
Internal and external gear meshing load simulations.
Bearing-ring modelling and bearing-seat misalignment assessments.
Evaluate structural performance under multiple loading conditions, including external loads, gear meshing loads, actuation forces and transmitted torque.
Modelling & Meshing Create high-quality finite element meshes for complex cast and forged components using HyperMesh.
Manage large-scale multi-body finite element assemblies.
Ensure model quality, robustness and compliance with customer standards and best engineering practices.
Results Assessment & Fatigue Evaluation Analyse and interpret simulation results, including: Signed Von Mises stresses. Displacements. Contact pressures. Contact status.
Perform fatigue safety-factor assessments using FEMFAT.
Identify critical areas and provide engineering recommendations to improve component durability and structural integrity.
Reporting & Customer Interface Execute analyses according to customer calculation guidelines and recognised engineering best practices.
Work autonomously using own hardware and software environment.
Provide structured weekly progress reports detailing: Activity status. Analysis progress. Hours spent per task. Project risks and mitigation actions.
Prepare professional PowerPoint reports including: Model description. Boundary conditions. Material definitions. Connectivity setup. Load case overview. Results and conclusions.
Maintain full traceability of software versions, CAD revisions and calculation baselines.
Collaborate directly with customer engineering teams and communicate technical findings effectively.

Requirements

What you’ll need

PhD in Mechanical Engineering, Computational Mechanics, Structural Mechanics, Solid Mechanics or a related discipline preferred.
Minimum requirement: MSc in Mechanical Engineering or equivalent with a specialization in CAE and Structural Analysis.
Minimum 3 years of professional CAE / Structural FEA experience.
5+ years preferred, with experience in: Driveline systems. Powertrain components. Axles. Transmissions.
Experience in the automotive or heavy commercial vehicle industry is highly desirable.
Proven experience in the structural validation of cast and forged components as well as bolted assemblies under static and fatigue loading conditions.
Previous experience working as a CAE consultant or supplier to OEMs or Tier-1 companies is an advantage.
Expert-level structural analysis experience with: Abaqus 2024. PERMAS v20.
Proficiency with: Altair HyperMesh 2024.1. FEMFAT 2024.1. Altair HyperView 2024.1.
Strong knowledge of: Structural mechanics. Strength of materials. Fatigue theory and stress-life methodologies. Contact mechanics. Bolted-joint design and verification.
Good understanding of driveline architecture, differentials, bearings and gear systems.
Professional proficiency in English (written and spoken) is mandatory.
Italian is considered an advantage.
Strong autonomy and ability to work independently.
High level of accuracy and attention to detail.
Strong analytical and problem-solving skills.
Excellent communication and technical reporting abilities.
Ownership mindset and commitment to delivering high-quality engineering work.
Hands-on experience in e-axle or electrified driveline structural validation.
Advanced hexa-dominant meshing expertise.
Scripting and automation skills (Python, Tcl/Tk) for model generation and post-processing.

Benefits

Comp & perks

Smooth Integration: Our technical and personal onboarding process ensures you can easily and quickly adapt to your new role.
Career Development: Growth and advancement opportunities within the company, including mentoring and training programs tailored to your professional goals.
Work Flexibility: Options for remote work and flexible hours to help maintain a healthy work-life balance.
Collaborative Environment: A company culture that fosters open communication, teamwork, and innovative thinking.
Community Connection: Regular employee events and activities that build camaraderie and strengthen team bonds.
Recognition and Support: A commitment to acknowledging your contributions and providing the necessary support for you to thrive professionally.

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Applicant Tracking System Keywords

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Hard Skills & Tools

CAE analysisfinite element modelingnonlinear static analysisfatigue analysiscontact mechanicsstructural validationscriptingautomationmeshingstructural analysis

Soft Skills

analytical skillsproblem-solving skillsattention to detailcommunication skillstechnical reportingautonomyownership mindsetcollaborationorganizational skillscustomer interface

Certifications

PhD in Mechanical EngineeringMSc in Mechanical Engineering