Samtec

Principal Product Engineer - FEA

Samtec • $100K — $130K *
New Albany, IN 47150In-Person
Aerospace & Defense
8 - 10 years of experience
Today
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Job Overview by Ladders

Qualifications

  • 10+ years of experience in structural analysis using commercial FEA tools.
  • Deep understanding of mechanics, dynamic response, and material behavior including creep and fatigue.
  • Expert in commercial FEA tools (e.g., ANSYS, Abaqus, Nastran).
  • Skilled in complex mechanical systems modeling, including nonlinear analysis and coupled thermo-mechanical modeling.
  • Proficient in non-linear solution strategies and solver selection for complex problems.
  • Strong record in influencing engineering decisions through simulation results.
  • Excellent technical communication skills with multidisciplinary teams and customers.

Responsibilities

  • Lead advanced finite element analysis (FEA) studies for complex mechanical systems.
  • Conduct Design of Experiments (DOE) to assess sensitivity to various factors.
  • Analyze mechanical loading and evaluate fatigue, damage, and reliability metrics.
  • Conduct simulations to evaluate material behavior and inform design choices.
  • Mentor simulation engineers and standardize FEA workflows and practices.
  • Effectively communicate findings during design reviews and presentations.
  • Manage multiple projects in a fast-paced environment.

Benefits

  • Technical mentorship opportunities.
  • Collaborative work environment with cross-functional teams.
  • Chance to influence design and engineering decisions directly.
  • Engagement in cutting-edge simulation and analysis methodologies.
Full Job Description
Description

Position at Samtec, Inc

Summary/Objective: The Principal Product Engineer - FEA leads advanced structural and thermal analyses for complex mechanical systems. This role emphasizes deep expertise in finite elements analysis (FEA), particularly non-linear behavior, shock, vibration, creep, thermal loading, and stress relaxation phenomena. The engineer will serve as a subject matter expert and guide design teams within New Product or Sustaining Product Engineering ensuring compliance with demanding environmental and performance requirements.

Essential Functions/ Responsibilities:
  • Lead and perform complex finite element analysis (FEA) studies using industry standard tools (e.g., ANSYS Mechanical, LS-DYNA) for static, dynamic, shock, vibration, and thermo-mechanical loading across components and assemblies.
  • Lead simulation-driven studies and analytical Design of Experiments (DOE) to quantify sensitivity to geometry, materials, process parameters, and boundary conditions.
  • Multi-step, history-dependent mechanical and thermo-mechanical loading, including manufacturing and assembly load sequences, across components and assemblies.
  • Analyze and predict fatigue, damage accumulation, and long-term reliability using physics-based metrics such as strain energy density, stress/strain range, and time and force dependent deformation behavior.
  • Utilize simulation to evaluate material behavior in metals, polymers, and composite materials to inform design and material selection.
  • Serve as a subject matter expert for advanced mechanics, structural integrity, and reliability of mechanical assemblies and systems.
  • Conduct coupled thermo-mechanical simulations to evaluate creep, thermal fatigue, and long-term material deformation under sustained loads.
  • Develop, implement, and validate advanced material models including viscoelastic, creep, and stress relaxation behavior, particularly at elevated temperatures.
  • Develop and correlate analytical models with physical test data to ensure accuracy and predictive capability.
  • Provide technical mentorship for simulation engineers and lead standardization of FEA workflows, best practices, and analysis templates.
  • Partner closely with cross-functional teams to ensure robust, manufacturable solutions that meet customer requirements.
  • Communicate analytical findings effectively in design reviews, technical reports, and presentations to internal and external customers.
  • Work effectively across multiple projects and priorities in a demanding environment.

"The responsibilities as defined are intended to serve as a general guideline for this position. Employees may be asked to perform additional tasks depending on strengths and capabilities."

Required Experience:
  • 10+ years of experience conducting structural analysis using commercial FEA tools, with experience using advanced techniques such as shock, vibration, and coupled thermo-mechanical FEA.
  • Deep understanding of mechanics, dynamic response, and material behavior (including creep, stress relaxation, and fatigue).
  • Expert with commercial FEA tools and design software (e.g., ANSYS, Abaqus, Nastran, SolidWorks).
  • Proven expertise in modeling complex mechanical systems, encompassing contact, anisotropic materials such as fiber-filled plastics, and nonlinear modeling. Skilled in coupled thermo-mechanical modeling, including analyses of creep, thermal loading, and stress relaxation. Experienced in shock, vibration, and reliability modeling and qualification of mechanical systems.
  • Expertise in non-linear solution strategies, convergence control, contact stabilization, and solver selection for complex problems.
  • Proven record of accomplishment interpreting complex simulation results and influencing engineering decisions and product design.
  • Must be able to manage multiple projects simultaneously as priorities can change quickly.
  • Excellent technical communication (written and verbal) and experience interfacing with customers, multidisciplinary engineering teams, and non-technical stakeholders.


Preferred Experience:
  • Experience within electronic, defense, aerospace, energy, or high reliability industrial fields.
  • Knowledge and experience with manufacturing processes such as cold rolling, stamping, and injection molding and their impact on structural performance.
  • Experience with product test plan development and correlation of simulation results to test data.
  • Knowledge and experience with material testing and characterization methods (e.g., DMA, TMA, Stress Relaxation).
  • Leadership experience in mentoring engineers and driving improvements in analytical processes and methodologies.
  • Experience automating analysis workflows and post-processing using scripting or custom tools.

Education:
  • Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Materials Science or equivalent is required.
  • Master's degree or PhD is highly desirable but not required.


About Samtec

Samtec is a privately held $822MM global manufacturer of a broad line of electronic interconnect solutions, including High-Speed Board-to-Board, High-Speed Cables, Mid-Board and Panel Optics, Precision RF, Flexible Stacking, and Micro/Rugged components and cables. With 40+ locations serving approximately 125 countries, Samtec?s global presence enables its unmatched customer service. Samtec designs and manufactures products, including connectors, cable assemblies, and system solutions, for all markets and applications, including data center, telecommunications, industrial, medical, military, aerospace, and automotive industries.
Learn more about Samtec
Size
5,000 employees
Industry
Manufacturing & Automotive
Founded
1976
* Ladders Estimates

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