RepRally · 5 days ago
CAE Engineer
San Jose, CA
Full-time
Onsite
Senior Level
5+ years expRepRally is a stealth-mode battery startup developing cutting-edge battery technology. They are seeking a CAE Mechanical Engineer to lead high-fidelity structural simulations for lithium-ion battery systems and collaborate with design, test, and manufacturing teams to inform design architecture through simulation-driven insights.
MarketplaceSoftware
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
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
RepRally
Developer of a wholesale platform to eliminate the barriers to distribution and broaden consumer access to high-quality products.
11-50 employees
H1B Sponsorship
RepRally has a track record of offering H1B sponsorships. Please note that this does not
guarantee sponsorship for this specific role. Below presents additional info for your
reference. (Data Powered by US Department of Labor)
Distribution of Different Job Fields Receiving Sponsorship
Represents job field similar to this job
Trends of Total Sponsorships
2025 (2)
2024 (1)
Funding
Current Stage
Early StageTotal Funding
unknownKey Investors
GreylockIndicator Ventures
2024-09-09Series A
2023-11-13Seed
2023-07-01Pre Seed
Leadership Team
Justin Donovan
CEO, Co-Founder
Daryn Lam
Co-Founder
Recent News
muventures
2023-08-30
Company data provided by crunchbase