Stealth Battery Startup · 3 days ago
CAE Engineer
San Jose, CA
Full-time
Onsite
Senior Level
$186K/yr - $265K/yr
5+ years expStealth Battery Startup is a stealth-mode company developing cutting-edge battery technology aimed at revolutionizing the industry for a cleaner energy future. They are seeking a CAE Mechanical Engineer to lead high-fidelity structural simulations for lithium-ion battery systems, collaborating closely with design and manufacturing teams to ensure reliable hardware development.
Utilities
Responsibilities
Perform mechanical FEA under diverse loading conditions including crush, vibration, drop, thermal expansion, swelling, crash and underbody impact
Build and refine detailed simulation models using CAD and empirical inputs, with rigorous attention to mesh quality, materials, contacts, and boundary conditions
Conduct simulations using Abaqus, ANSYS, LS-DYNA, or similar tools; analyze results to assess deformation, failure risk, and design sensitivity
Correlate simulation outputs with physical test data (e.g., strain gauges, displacements, fracture behavior) to validate and improve model fidelity
Rapidly iterate on design alternatives and provide clear, actionable simulation feedback to design teams
Own analysis workflows for: First Mode and Modal Analysis, Shock and Vibration Evaluation, Underbody Impact Scenarios, Side Pole Impact
Contribute to the selection and integration of solver tools, pre/post-processors, and overall CAE infrastructure
Define, document, and continuously improve best practices and workflows to ensure robust, repeatable analysis pipelines
Develop and validate material models for CAE use—ideally by designing and executing custom test programs to generate material cards
Support the development of fatigue analysis methodologies, particularly for polymers or adhesive joints
Lay the foundation for in-house battery crash and impact simulation capabilities: Model mechanical behavior of cells during impact
Collaborate with OEMs on vehicle-level integration and crash safety strategy
Partner with Product Development on mechanical hardware, especially: Underbody protective elements, Structural enclosures, Pack framing and load-bearing components
Contribute to the design and optimization of next-generation battery compression systems, including advanced “quilted” or pre-formed plate concepts
Qualification
Required
B.S. or M.S. in Mechanical Engineering, Applied Mechanics, or related discipline
5+ years of experience in mechanical FEA, ideally within battery systems or similar dense electro-mechanical assemblies
Proven proficiency in FEA tools such as Abaqus, ANSYS, or LS-DYNA; deep understanding of crash, vibration, and non-linear analyses preferred
Strong skills in model setup (meshing, contact definition, material property assignment, boundary condition management)
Demonstrated ability to correlate simulation to test data and validate model accuracy
Excellent communicator—capable of presenting simulation results, limitations, and trade-offs to multidisciplinary teams
Comfortable working in fast-paced, iterative environments with evolving product requirements
Company
Stealth Battery Startup
We're a stealth-mode battery startup.
11-50 employees
Funding
Current Stage
Early StageCompany data provided by crunchbase