Virtual Propulsion Engineer – Focus with either Structural, Durability, Dynamics, NVH, Sealing, Fastening, Cranktrain and/or Fatigue Analysis
General Motors · Warren, Michigan, United States
Job Description
The Virtual Propulsion Engineer is responsible for developing and executing advanced Computer-Aided Engineering (CAE) analyses to support the design, development, validation, and optimization of propulsion systems across Internal Combustion Engine (ICE), Transmissions, Drive Units, Electric Motors, and Rechargeable Energy Storage Systems(RESS) which include Hybrid (PHEV), Battery Electric Vehicle (BEV), and future propulsion technologies. This role partners closely with Design Responsible Engineers (DREs), Advanced Project Engineers, Validation Engineers, Manufacturing Engineers, and Suppliers to deliver simulation-driven engineering solutions that improve product performance, quality, durability, efficiency, and time-to-market. The engineer serves as a key technical contributor in virtual product development through advanced simulation, automation, correlation, and continuous capability development.
The Role
As a Virtual Propulsion Engineer, you will provide analytical leadership and technical expertise supporting propulsion structures, castings, battery systems, cranktrains, rotating machinery, bearings, gears, sealing systems, fastening systems, durability, fatigue, stiffness, dynamics, and Noise, Vibration, and Harshness (NVH) performance. You will develop high-fidelity simulation models, evaluate component and system designs, identify risks early in the development process, and provide actionable design recommendations that drive engineering decisions.
You will also help advance organizational CAE capabilities through the development of new methodologies, automation tools, simulation workflows, correlation processes, and AI-enabled engineering solutions to improve prediction accuracy, execution speed, and engineering efficiency.
What You'll Do
Product Development & Analysis
- Perform structural, durability, fatigue, stiffness, sealing, fastening, dynamics, and NVH analyses for propulsion components and systems.
- Evaluate batteries, electric drive units, engines, transmissions, cranktrain, castings, structural housings, sealing interfaces, fastening systems, and supporting hardware.
- Build, troubleshoot, and execute advanced finite element models to assess strength, durability, vibration, acoustic performance, thermal-mechanical interactions, and system reliability.
- Support concept development, design maturation, design validation, and production launches through simulation-driven engineering.
- Generate analytical data and design recommendations to ensure products meet performance, durability, reliability, safety, and customer requirements.
- Conduct root cause investigations, failure analysis, and performance optimization studies using simulation, test data, and field feedback.
- Perform Design of Experiments (DOE), optimization studies, sensitivity analyses, robustness evaluations, and reliability assessments.
Modeling & Simulation
- Retrieve, modify, and prepare CAD geometry for finite element model creation.
- Develop high-quality FEA models including geometry cleanup, meshing, material definition, contact interactions, boundary conditions, and load case development.
- Perform linear and nonlinear structural analyses, modal analyses, forced response analyses, fatigue assessments, transient dynamics simulations, and multidisciplinary studies.
- Develop scalable and reusable simulation models that support program execution and capability growth.
Correlation & Validation
- Correlate simulation results with laboratory testing, vehicle testing, and field data.
- Collaborate with test engineers to improve test methods, fidelity, and develop first-time capable virtual validation processes.
Technical Leadership & Collaboration
- Partner with DREs, program teams, validation teams, manufacturing engineers, suppliers, and leadership to influence product decisions.
- Present complex technical findings clearly and confidently to engineering teams and leadership.
- Translate simulation results into actionable engineering decisions and business recommendations.
- Support resolution of technical challenges throughout the product lifecycle.
- Mentor engineers in CAE tools, simulation methodologies, and analytical best practices.
Capability Development & Innovation
- Lead development and deployment of new CAE methodologies, workflows, standards, and best practices.
- Identify capability gaps and drive continuous improvement initiatives.
- Develop automation tools and digital workflows using programming and scripting techniques.
- Advance virtualization strategies that reduce physical testing while improving confidence in engineering decisions.
- Explore and implement AI/ML, data analytics, and intelligent automation techniques to improve predictive accuracy and engineering efficiency.
- Create and maintain technical documentation, procedures, standards, and reusable templates.
Benchmarking & Continuous Improvement
- Participate in competitive benchmarking activities.
- Drive cost reduction, mass optimization, reliability improvements, and performance enhancement initiatives.
- Support organizational goals related to virtual validation and transition toward a more risk-based (FMEA) engineering culture.
Required Qualifications
- Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Physics, or related engineering discipline.
- Minimum 5 years of experience in finite element modeling and CAE analysis.
- Strong understanding of mechanics of materials, structural analysis, durability, fatigue, vibration, and engineering fundamentals.
- Experience building and executing FEA models from CAD geometry.
- Working knowledge of propulsion systems, including ICE, hybrid, electric propulsion, battery systems, and supporting structures.
- Experience performing root cause analysis and translating analytical results into design recommendations.
- Demonstrated ability to solve complex engineering problems with limited direction.
- Excellent verbal, written, presentation, and interpersonal communication skills.
- Proven ability to work effectively across cross-functional teams.
- Proficiency with Microsoft Office and Google Workspace.
Preferred Qualifications
- Master’s degree or Ph.D. in Mechanical Engineering, Aerospace Engineering, Structural Engineering, Acoustics, Physics, or related discipline.
- Experience supporting full vehicle or propulsion product development from concept through production launch.
- Advanced knowledge of nonlinear analysis, failure theories, multi-axial fatigue, dynamics, and signal processing.
- Experience with AI/ML applications, digital engineering tools, and simulation automation.
- Expertise in one or more of the following areas:- Durability & Fatigue Analysis
- Structural Analysis
- Dynamics & NVH
- Battery Structural Analysis
- Cranktrain Analysis
- Sealing, Fastening & Joint Integrity
- Reliability Engineering
- Experience in one or more of the following:- Abaqus (Implicit/Explicit/CAE)
- OptiStruct
- HyperMesh
- HyperView
- ANSA
- Nastran
- ANSYS
- Actran
- ADAMS/MBD
- AMEsim
- SimLab
- nCode DesignLife
- Simcenter 3D Motion
- Fe-Safe
- AVL Excite
- FEMFAT
- DIGIMAT
- Moldflow
- Matlab
- iSIGHT
- NX/Teamcenter
- Python
- VCollab
GM does not provide immigration-related sponsorship for this role. Do not apply for this role if you will need GM immigration sponsorship now or in the future. This includes direct company sponsorship, entry of GM as the immigration employer of record on a government form, and any work authorization requiring a written submission or other immigration support from the company (e.g., H1-B, OPT, STEM OPT, CPT, TN, J-1, etc).
About GM
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