OPT CAE Engineer Jobs
CAE Engineer jobs are a strong fit for F-1 OPT students with degrees in mechanical, aerospace, or structural engineering. Most roles qualify as STEM OPT, giving you up to 36 months of work authorization. Employers in automotive, aerospace, and defense regularly sponsor H-1B visas for this specialty.
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CAE Engineer
Position Description:
We are looking for an experienced structural CAE engineer to lead high-voltage battery internals and related system structural design using CAE tools. You will work with battery design and release engineers on cutting-edge battery technologies to ensure the battery functional environment operates within specified conditions. As a collaborative team player, you will create impact by working across the Electrified Powertrain Engineering organization and with key stakeholders of the battery business. Global Electrified Powertrain Engineering Team is a growing team committed to bringing efficiency and value into the battery architecture through close collaboration with global suppliers. Together, our team works to understand our changing world, identify new opportunities, and take action to design and innovate for the future of mobility - vehicles and surrounding experiences.
Skills Required:
- Abaqus - Primary FEA solver (required)
- HyperMesh - Pre-processing, meshing, and model setup
- nCode or fe-safe - Fatigue and durability analysis
Experience Required:
- 4+ years of experience working with structural components and designs in an engineering environment.
- Bachelor's degree in Mechanical or Structural Engineering.
- Broad experience using ABAQUS, Hypermesh, ncode or FeSafe and 3DX.
- Minimum of 3 years of working in Abaqus performing non-linear FEA, 5 preferred.
Experience Preferred:
- 5 or more years of experience specifically in CAE structural modeling and simulation analysis techniques using ABAQUS or equivalent, including experience selecting appropriate solution procedures for complex non-linear problems.
- M.S. in Mechanical Engineering or equivalent degree.
- Working knowledge of ABAQUS, OptiStruct Non-Linear, HyperMesh, HyperView, ABAQUS Viewer, Teamcenter, 3DEXPERIENCE (3DX), or equivalent tools (ANSYS, etc.).
- Working knowledge of CAE tools for fatigue assessments such as FEMFAT, nCode, fe-safe, or equivalent.
- Strong experience in correlating complex non-linear CAE models with physical test data, including sensitivity analysis and model tuning for improved accuracy.
- Extensive knowledge of various structural materials, high-strength material behavior, energy flow theory and analysis methods, fracture mechanics, and crack initiation/propagation.
- Working knowledge and experience using CAE pre-processing tools such as HyperMesh or equivalent for geometry cleanup and meshing, and ABAQUS, Nastran, or equivalent for CAE model solving and post-processing.
- Proficiency in ABAQUS scripting (Python) for model automation and advanced post-processing.
- Familiarity with sheet metal design specifications, sealing design, structural testing setup, and data collection.
- Familiarity with thermal-mechanical coupled analysis that considers temperature-dependent material properties, thermal expansion, and effects on structural integrity.
- Proven record of innovative applications and ability to introduce new ideas for product development.
- Working knowledge of optimization CAE tools such as modeFRONTIER, iSight, HEEDS, Tosca, or OptiStruct.
- Experience in physical testing is a plus.
- Ability to mentor junior engineers and collaborate effectively as a team player.
- Strong verbal and written communication and interpersonal skills.
- Experience with variability, robustness, and Six Sigma methodologies.
Education Required:
MASTER'S DEGREE (w/ FEA courses taken)
Additional Information:
POSITION IS HYBRID / (4 days per week in the office / Monday to Thursday)
- Build 3D battery internal structural analysis CAE models from CAD designs.
- Debug complex finite element (FE) models independently.
- Perform 3D structural simulations on high-voltage battery packs at the system, subsystem, and component levels to support internal design development, utilizing non-linear FEA codes such as ABAQUS, ANSYS, or OptiStruct Non-Linear, including pre- and post-processing with HyperMesh, HyperView, and ABAQUS Viewer.
- Evaluate 3D structural analysis results and provide technical feedback and design direction to vehicle program and battery pack design teams.
- Collaborate with vehicle-level teams to obtain boundary conditions for battery pack structural-level simulations.
- Partner with battery lab and vehicle-level testing teams; specify instrumentation for data collection; process physical structural test results and use the data to correlate CAE models.
- Coordinate with extended overseas CAE teams for meshing and geometric cleanup tasks.
- Compile professional, organized, and structured reports detailing completed CAE work, including recommendations and conclusions.
Job Title:
CAE Engineer
Position Description:
We are looking for an experienced structural CAE engineer to lead high-voltage battery internals and related system structural design using CAE tools. You will work with battery design and release engineers on cutting-edge battery technologies to ensure the battery functional environment operates within specified conditions. As a collaborative team player, you will create impact by working across the Electrified Powertrain Engineering organization and with key stakeholders of the battery business. Global Electrified Powertrain Engineering Team is a growing team committed to bringing efficiency and value into the battery architecture through close collaboration with global suppliers. Together, our team works to understand our changing world, identify new opportunities, and take action to design and innovate for the future of mobility - vehicles and surrounding experiences.
Skills Required:
- Abaqus - Primary FEA solver (required)
- HyperMesh - Pre-processing, meshing, and model setup
- nCode or fe-safe - Fatigue and durability analysis
Experience Required:
- 4+ years of experience working with structural components and designs in an engineering environment.
- Bachelor's degree in Mechanical or Structural Engineering.
- Broad experience using ABAQUS, Hypermesh, ncode or FeSafe and 3DX.
- Minimum of 3 years of working in Abaqus performing non-linear FEA, 5 preferred.
Experience Preferred:
- 5 or more years of experience specifically in CAE structural modeling and simulation analysis techniques using ABAQUS or equivalent, including experience selecting appropriate solution procedures for complex non-linear problems.
- M.S. in Mechanical Engineering or equivalent degree.
- Working knowledge of ABAQUS, OptiStruct Non-Linear, HyperMesh, HyperView, ABAQUS Viewer, Teamcenter, 3DEXPERIENCE (3DX), or equivalent tools (ANSYS, etc.).
- Working knowledge of CAE tools for fatigue assessments such as FEMFAT, nCode, fe-safe, or equivalent.
- Strong experience in correlating complex non-linear CAE models with physical test data, including sensitivity analysis and model tuning for improved accuracy.
- Extensive knowledge of various structural materials, high-strength material behavior, energy flow theory and analysis methods, fracture mechanics, and crack initiation/propagation.
- Working knowledge and experience using CAE pre-processing tools such as HyperMesh or equivalent for geometry cleanup and meshing, and ABAQUS, Nastran, or equivalent for CAE model solving and post-processing.
- Proficiency in ABAQUS scripting (Python) for model automation and advanced post-processing.
- Familiarity with sheet metal design specifications, sealing design, structural testing setup, and data collection.
- Familiarity with thermal-mechanical coupled analysis that considers temperature-dependent material properties, thermal expansion, and effects on structural integrity.
- Proven record of innovative applications and ability to introduce new ideas for product development.
- Working knowledge of optimization CAE tools such as modeFRONTIER, iSight, HEEDS, Tosca, or OptiStruct.
- Experience in physical testing is a plus.
- Ability to mentor junior engineers and collaborate effectively as a team player.
- Strong verbal and written communication and interpersonal skills.
- Experience with variability, robustness, and Six Sigma methodologies.
Education Required:
MASTER'S DEGREE (w/ FEA courses taken)
Additional Information:
POSITION IS HYBRID / (4 days per week in the office / Monday to Thursday)
- Build 3D battery internal structural analysis CAE models from CAD designs.
- Debug complex finite element (FE) models independently.
- Perform 3D structural simulations on high-voltage battery packs at the system, subsystem, and component levels to support internal design development, utilizing non-linear FEA codes such as ABAQUS, ANSYS, or OptiStruct Non-Linear, including pre- and post-processing with HyperMesh, HyperView, and ABAQUS Viewer.
- Evaluate 3D structural analysis results and provide technical feedback and design direction to vehicle program and battery pack design teams.
- Collaborate with vehicle-level teams to obtain boundary conditions for battery pack structural-level simulations.
- Partner with battery lab and vehicle-level testing teams; specify instrumentation for data collection; process physical structural test results and use the data to correlate CAE models.
- Coordinate with extended overseas CAE teams for meshing and geometric cleanup tasks.
- Compile professional, organized, and structured reports detailing completed CAE work, including recommendations and conclusions.
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Get Access To All JobsTips for Finding OPT Sponsorship as a CAE Engineer
Target STEM-designated degree programs
CAE Engineer roles typically qualify for the 24-month STEM OPT extension when your degree is in mechanical, aerospace, civil, or structural engineering. Confirm your program's CIP code with your DSO before applying to maximize your authorized work period.
Focus on simulation-heavy industries
Automotive OEMs, aerospace primes, and defense contractors run large CAE teams and have established H-1B sponsorship pipelines. These employers file in high volumes annually, making them more likely to sponsor engineers transitioning off OPT.
Lead with specific solver experience
Hiring managers screen by software stack. Listing Abaqus, Ansys, Nastran, or LS-DYNA prominently on your resume signals technical readiness and reduces ramp-up cost, which directly improves your sponsorship case with cost-conscious employers.
Apply early relative to your OPT end date
H-1B cap-subject petitions must be filed by April 1 for an October 1 start. If your OPT expires before October 1, ask employers about cap-exempt options or whether a cap-gap extension applies to your situation.
Frame academic simulation projects as professional experience
Finite element analysis projects, crash simulations, or thermal modeling from graduate coursework are directly relevant. Quantify results where possible, such as mesh accuracy improvements or reduced solve times, to strengthen your candidacy against experienced engineers.
Ask about sponsorship history before final interviews
Before investing in lengthy technical rounds, confirm the employer has sponsored H-1B visas for engineering roles before. OFLC disclosure data is publicly available and shows which companies have filed LCAs for CAE or simulation engineering positions.
CAE Engineer OPT: Frequently Asked Questions
Do CAE Engineer jobs qualify for the STEM OPT extension?
Most CAE Engineer roles qualify for the 24-month STEM OPT extension, provided your degree is in a STEM-designated field such as mechanical engineering, aerospace engineering, or applied mechanics. Your DSO can confirm eligibility by checking your program's CIP code. The extension must be applied for before your initial 12-month OPT period expires, so plan ahead.
Which industries hire the most CAE Engineers willing to sponsor OPT students?
Automotive manufacturers and suppliers, aerospace primes, and defense contractors employ the largest CAE teams and have consistent H-1B sponsorship track records. Companies like tier-one automotive suppliers and aircraft manufacturers file LCAs for simulation engineers regularly. You can browse OPT-friendly CAE Engineer openings across these industries on Migrate Mate, which filters specifically for roles open to F-1 OPT candidates.
What happens to my OPT authorization if my CAE Engineer job ends?
If your employment ends, you have a 60-day grace period to find a new OPT-qualifying job, transfer to another visa status, or depart the United States. Unemployment time also counts against your OPT period, so you cannot exceed 90 days of cumulative unemployment on standard OPT or 150 days on STEM OPT extension. Notify your DSO immediately when employment ends.
Can I work as a contract or consulting CAE Engineer on OPT?
Yes, but with conditions. Contract and consulting arrangements are permitted on OPT as long as the work is directly related to your degree field and you are actively engaged in simulation or engineering work, not just administration. Self-employment structures require careful review with your DSO. Short-gap periods between contracts still count as unemployment days against your authorized totals.
What software skills make OPT students more competitive for CAE Engineer roles?
Employers consistently prioritize experience with finite element analysis solvers such as Abaqus, Ansys Mechanical, Nastran, or LS-DYNA. Familiarity with pre- and post-processing tools like HyperMesh, ANSA, or ICEM CFD adds further value. For fluid simulation roles, OpenFOAM or Fluent experience is highly sought. Candidates who can demonstrate results from academic or internship projects using these tools are significantly more competitive for sponsored positions.