The Senior Finite Element Analysis (FEA) Engineer develops and applies advanced numerical models to support optical manufacturing, product reliability, and design decision-making. This role focuses on thermo-mechanical behavior of precision glass molding tooling, temperature-dependent flow of molten glass during forming processes, and the structural integrity of optical and opto-mechanical assemblies exposed to extreme thermal and vibrational environments. The position partners closely with optics, materials, manufacturing, and test teams to reduce risk, accelerate development, and improve product performance.

Responsibilities:

Develop and validate thermo-mechanical FEA models to predict mold expansion, contraction, stress, and distortion as a function of temperature and thermal cycling.
Build coupled thermal–structural and CFD-informed models to characterize molten glass flow, viscosity effects, and forming-induced stresses during lens molding processes.
Perform structural, modal, vibration, shock, and thermal analyses of optical and opto-mechanical assemblies across defined operating and survival environments.
Define and implement appropriate material models (elastic, plastic, viscoelastic, creep, and temperature-dependent properties) and contact conditions for metals, glasses, ceramics, and composites.
Correlate simulation results with experimental and test data; support test planning, root-cause investigations, and design trade studies.
Partner with optics, materials, manufacturing, and test engineers to inform design decisions and manufacturing process improvements.
Document assumptions, methodologies, results, and conclusions in clear, concise engineering reports suitable for design reviews, customers, and regulatory or qualification scrutiny.

Required

MS or PhD in Mechanical Engineering, Aerospace Engineering, or a related discipline.
7+ years of hands-on experience performing linear and nonlinear FEA for structural and thermal problems.
Advanced proficiency with commercial FEA tools including:
- - Ansys (Mechanical, Fluent, Sherlock)
  - Abaqus or NASTRAN
  - Pre/post-processing tools (HyperMesh/HyperWorks, FEMAP, or similar)
Strong foundation in continuum mechanics, heat transfer, and materials behavior.
Experience developing custom material models using Fortran or C/C++ (UMAT/VUMAT in Abaqus, usermat in Ansys, or equivalent).
Demonstrated ability to independently scope analyses and translate physical problems into robust, validated simulation models.

Preferred

Experience modeling temperature-dependent viscous flow, glass transition behavior, or material forming processes (glass, polymer, or metal).
Experience with coupled CFD–thermal–structural analyses, particularly for manufacturing or forming applications.
Python scripting for FEA automation, parametric studies, and batch post-processing (Ansys APDL, Abaqus Python API, or similar).
Experience with MATLAB or similar tools for data analysis and visualization.
Familiarity with CAD systems such as Creo, SolidWorks, or equivalent for geometry interaction and model preparation.
Experience in optical, opto-mechanical, or precision manufacturing environments.
Knowledge of manufacturing processes (machining, molding, assembly) and their impact on structural and thermal performance.

Background in automotive, aerospace, defense, or precision equipment industries.

Lightpath Technologies Inc

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Sr. Finite Element Analysis Engineer