Mechanical Design Engineer, Ansys FEA/Thermal

About the Role

SARACA is seeking Mechanical Design Engineers at multiple experience levels to develop mechanical components and assemblies from concept through mass production for advanced energy storage systems. The roles emphasize FEA-driven structural design, sheet metal, weldments, weatherproofing, sealing systems, and design for manufacturability (DFMA).

Key Responsibilities

• Develop conceptual and detailed mechanical designs for next-generation battery systems and structural assemblies.
• Perform structural analysis using Ansys Finite Element Analysis (FEA) and engineering hand calculations.
• Design and optimize sheet metal components, weldments, enclosures, and sealing systems.
• Collaborate with test engineers to develop test plans and establish material libraries for FEA.
• Validate designs through physical testing and FEA correlation.
• Apply design for manufacturability and assembly (DFMA) principles.
• Present design concepts, structural analyses, and test results during engineering and leadership design reviews.
• Conduct root cause analysis of structural failures and implement corrective design solutions.
• Support the transition of mechanical components and assemblies from concept to high-volume manufacturing.
• For the Staff-level role, establish structural analysis methodologies, pass/fail criteria, and calculation tools for standard load cases.

Requirements & Tech Stack

• Bachelor’s degree in Mechanical Engineering or a related field.
• Experience in mechanical design, structural analysis, and CAD modeling, appropriate to the position level.
• Proficiency in SolidWorks modeling.
• Knowledge of structural engineering fundamentals and FEA-based design validation.
• Strong analytical, problem-solving, communication, and cross-functional collaboration skills.
• Self-driven mindset with the ability to manage priorities and meet demanding project timelines.
• Ansys FEA
• SolidWorks
• Structural Analysis and Mechanical Design
• Finite Element Analysis (FEA)
• Sheet Metal Design and Weldments
• GD&T – ASME Y14.5
• Design for Manufacturing and Assembly (DFMA)
• Material Testing and FEA Correlation
• Root Cause Analysis
• Structural Optimization

Position-Specific Experience

• Mechanical Design Engineer II

• 0–2 years of industry experience in mechanical design.

• Coursework in mechanical structures design fundamentals and FEA theory.

• Experience with SolidWorks CAD modeling.

• Knowledge of 2D drafting and GD&T (ASME Y14.5) is preferred.

• Senior Mechanical Design Engineer

• 4+ years of industry experience in mechanical design and structural analysis.

• Experience designing complex mechanical structures and performing FEA.

• Proficiency in SolidWorks modeling, drafting, and GD&T (ASME Y14.5).

• Experience with DFMA, particularly sheet metal, stampings, and weldments.

• Staff Mechanical Design Engineer

• 7+ years of industry experience in mechanical design and structural analysis.

• Strong experience leading structural analysis using Ansys FEA, including static, dynamic, linear, and nonlinear simulations.

• Expertise in structural load cases such as transport shock and vibration, seismic, wind, snow, and lifting.

• Experience developing analysis methodologies, pass/fail criteria, and engineering calculation tools.

• Knowledge of ASCE 7-22 and AISC-360 is preferred.