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:
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Develop and validate thermo-mechanical FEA models to predict mold expansion, contraction, stress, and distortion as a function of temperature and thermal cycling.
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Build coupled thermal–structural and CFD-informed models to characterize molten glass flow, viscosity effects, and forming-induced stresses during lens molding processes.
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Perform structural, modal, vibration, shock, and thermal analyses of optical and opto-mechanical assemblies across defined operating and survival environments.
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Define and implement appropriate material models (elastic, plastic, viscoelastic, creep, and temperature-dependent properties) and contact conditions for metals, glasses, ceramics, and composites.
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Correlate simulation results with experimental and test data; support test planning, root-cause investigations, and design trade studies.
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Partner with optics, materials, manufacturing, and test engineers to inform design decisions and manufacturing process improvements.
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Document assumptions, methodologies, results, and conclusions in clear, concise engineering reports suitable for design reviews, customers, and regulatory or qualification scrutiny.
Required
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MS or PhD in Mechanical Engineering, Aerospace Engineering, or a related discipline.
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7+ years of hands-on experience performing linear and nonlinear FEA for structural and thermal problems.
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Advanced proficiency with commercial FEA tools including:
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Ansys (Mechanical, Fluent, Sherlock)
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Abaqus or NASTRAN
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Pre/post-processing tools (HyperMesh/HyperWorks, FEMAP, or similar)
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Strong foundation in continuum mechanics, heat transfer, and materials behavior.
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Experience developing custom material models using Fortran or C/C++ (UMAT/VUMAT in Abaqus, usermat in Ansys, or equivalent).
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Demonstrated ability to independently scope analyses and translate physical problems into robust, validated simulation models.
Preferred
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Experience modeling temperature-dependent viscous flow, glass transition behavior, or material forming processes (glass, polymer, or metal).
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Experience with coupled CFD–thermal–structural analyses, particularly for manufacturing or forming applications.
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Python scripting for FEA automation, parametric studies, and batch post-processing (Ansys APDL, Abaqus Python API, or similar).
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Experience with MATLAB or similar tools for data analysis and visualization.
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Familiarity with CAD systems such as Creo, SolidWorks, or equivalent for geometry interaction and model preparation.
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Experience in optical, opto-mechanical, or precision manufacturing environments.
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Knowledge of manufacturing processes (machining, molding, assembly) and their impact on structural and thermal performance.
Background in automotive, aerospace, defense, or precision equipment industries.
