Senior Structural Hardware Engineer – ECU
Job Location:
Warren, OH - USA
Monthly Salary:
Posted on:
Vacancies:
Job Summary
Job Description
General Motors is at the forefront of the transformation of automotive with the electrification of our portfolio and the development of leading-edge central compute and autonomous capabilities. Our ECU Mechanical & Structural Design team is a dynamic high-energy and innovative group focused on developing robust mechanical architectures for next-generation ECUs (Electronic Control Units). The team is responsible for structural design analysis and validation of new ECU designs using engineering fundamentals CAD and CAE while also reviewing and approving production design changes.
We are seeking a high-performing Structural CAE Hardware Engineer interested in leading the in-house development of electronics design. You will be responsible for the structural analysis durability and validation of electrical controllers and supporting hardware for our next-generation SDV (Software Defined Vehicle) architecture. This role requires strong collaboration with cross-functional and external partners.
What Youll Do:
- Translate CTQs / vehicle requirements into structural requirements and design constraints (vibration shock crash loads mounting conditions environmental exposure etc.)
- Develop and execute structural simulation models (linear/nonlinear FEA) to assess strength stiffness fatigue and durability of ECU components and assemblies
- Perform analyses for vibration modal response random vibration mechanical shock and mechanical integrity under various loading conditions
- Evaluate and optimize designs for weight stiffness durability and manufacturability
- Support material selection joint design fasteners and structural interfaces to ensure robust performance
- Work with cross-functional teams (design EE manufacturing) to implement structural design improvements
- Develop validation plans and correlate CAE results with physical test data (lab and vehicle level)
- Provide structural inputs to DFMEA DRBFM and design reviews; clearly quantify risks failure modes and mitigations
- Present analysis results trade studies and recommendations at PDTs design reviews and leadership updates
Your Skills & Abilities (Required Qualifications):
- BS in Mechanical Engineering (or related discipline) with strong focus on solid mechanics and structural analysis
- 5 years of experience in structural analysis/design of electronic enclosures or similar systems (ECUs automotive components aerospace or industrial products)
- Hands-on experience with CAE/FEA tools (e.g. Abaqus ANSYS Mechanical Nastran HyperMesh or equivalent) and data analysis tools (e.g. MATLAB Python or similar)
Strong understanding of:
Stress strain deformation and failure theories
Linear and nonlinear FEA contact modeling and material modeling
Fatigue durability and vibration analysis (modal harmonic random vibration)
Bolted joints welds snap fits and other mechanical connections
Material behavior (metals plastics composites) under thermal and mechanical loading
Practical experience correlating CAE models to physical test results (vibration tables shock testing durability testing)
Ability to interpret system loads and boundary conditions and collaborate closely with design and test teams
Strong communication skills; able to present complex structural analyses clearly to both technical and non-technical stakeholders
Demonstrated ability to work across cross-functional and global teams and manage multiple programs in parallel
What Will Give You a Competitive Edge (Preferred):
- MS or PhD in Mechanical Engineering (Structures/Mechanics) or related field
- Automotive experience with vibration durability and environmental standards
- Experience with ECU housing design packaging and mechanical integration
- Familiarity with manufacturing processes (castings injection molding sheet metal machining) and their structural implications
- Experience integrating structural design into DFMEA/DRBFM/DFx processes
- Knowledge of multi-physics interactions (structural thermal coupling)
- Prior work with ECU designs
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Required Experience:
Senior IC
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