Senior CAE engineer at Dexmate in Santa Clara, CA

SENIOR CAE ENGINEER Location: Santa Clara Office WHAT YOU'LL DO As a CAE Engineer on the Dexmate Robotics team, you will be at the forefront of designing and validating mechanical systems for our next-generation manipulation robots. You'll guide design decisions using high-fidelity finite element models grounded in sound engineering principles, working closely with mechanical, electrical, controls, software, and manufacturing teams to bring unprecedented robotic capabilities to life. Core Responsibilities: • Develop and analyze comprehensive finite element models for robotic systems, from individual components to full assemblies • Conduct static, dynamic, structural, and multi-body dynamics (MBD) simulations to evaluate performance against key requirements for strength, stiffness, durability, and manipulation accuracy • Guide mechanical design teams with actionable insights and design direction based on rigorous analysis • Optimize structural designs to minimize weight while maximizing stiffness, reliability, and performance under real-world operational loads • Define and analyze load cases for manipulation tasks, impacts, handling scenarios, and day-to-day operations • Validate FEA models through experimental testing and iterate based on physical performance data • Challenge traditional CAE methods and pioneer more efficient, accurate approaches for robotic systems • Collaborate with controls engineers to understand dynamic load profiles and system-level performance requirements • Support root cause analysis and failure investigation for production issues • Develop CAE workflows, best practices, and documentation to scale analysis capabilities across the team WHAT YOU'LL BRING Required Qualifications: • Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Applied Mechanics, or related field with 5+ years of experience OR Master's degree with 3+ years of experience OR PhD in designing and analyzing mechanical systems using FEA and CAE tools • 3+ years of experience in designing and analyzing mechanical systems using FEA and CAE tools • Strong fundamentals in solid mechanics, structural dynamics, and material science • Proficiency in CAE software (Abaqus, ANSYS, LS-DYNA, COMSOL, OptiStruct, or equivalent) • Experience with both implicit and explicit finite element analysis • Demonstrated ability to conduct static, dynamic, and durability analyses • Strong understanding of mechanical design principles and ability to translate analysis into actionable design recommendations • Experience with experimental validation methods and correlation between simulation and physical testing • Excellent communication skills and ability to collaborate effectively across multidisciplinary teams • Self-motivated problem solver who can work independently on challenging technical problems Preferred Qualifications: • Advanced degree (MS/PhD) in Mechanical Engineering or related field • Experience in robotics, automation, or mechatronics industries • Proficiency with multi-body dynamics simulation (ADAMS, MuJoCo, PyBullet) • Experience analyzing aluminum structures, composites, and advanced materials • Knowledge of advanced joining methods (adhesives, welding, mechanical fasteners) • Expertise in non-linear analysis, contact mechanics, and material characterization • Proficiency in programming/scripting for automation (Python, MATLAB) • Experience with CAD software (SolidWorks, OnShape, CATIA, NX, etc.) • Familiarity with structural dynamics, vibration analysis, and modal testing • Experience with thermal-structural coupling and multi-physics simulations • Understanding of manufacturing processes and design for manufacturability • Knowledge of fatigue analysis and life prediction methodologies