Overview:
Expleo is a trusted partner for end-to-end, integrated engineering, quality services and management consulting for digital transformation. We help businesses harness unrelenting technological change to successfully deliver innovations that will help them gain a competitive advantage and improve the everyday lives of people around the globe.
We are seeking a Powertrain FEA Engineer to support the analysis, development, and optimisation of powertrain components within high-performance automotive programmes. The role focuses on the application of Finite Element Method (FEM) and Finite Element Analysis (FEA) to evaluate and enhance the structural, thermal, and dynamic performance of drivetrain systems.
Working closely with powertrain design engineers, system engineers, and validation teams, the successful candidate will use simulation tools to assess component durability, fatigue performance, and NVH characteristics before physical prototyping. This role plays a critical part in reducing development risk, improving efficiency, and ensuring components meet stringent performance, quality, and reliability targets.
The position offers the opportunity to contribute to the development of advanced propulsion technologies, including internal combustion powertrains, hybrid systems, and electrified drivetrains.
Responsibilities:
- Simulation & Structural Analysis
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Perform Finite Element Analysis (FEA) to evaluate stress, strain, deformation, and durability of powertrain components including engines, transmissions, gear systems, and electric drive units.
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Conduct thermal and coupled Multiphysics simulations to analyse temperature effects on powertrain components and materials.
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Analyse structural behaviour under operational loading conditions, ensuring components meet safety and performance requirements.
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Fatigue & Durability Assessment
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Perform fatigue analysis to predict the service life of components subjected to cyclic loading, such as gears, shafts, and bearings.
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Assess durability under real-world operating conditions to support design improvements and reliability targets.
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NVH & Dynamic Behaviour Analysis
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Conduct modal and dynamic simulations to assess vibration characteristics, natural frequencies, and resonance behaviour of drivetrain systems.
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Support NVH optimisation activities to improve vehicle refinement and reduce vibration transmission.
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Design Optimisation
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Interpret simulation results to recommend design improvements and optimisation strategies.
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Work with design engineers to improve strength-to-weight ratios, structural performance, and packaging efficiency.
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Support lightweighting initiatives while maintaining structural integrity and durability.
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Simulation Process Development
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Develop and improve simulation workflows including pre-processing, solver configuration, and post-processing methods.
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Support automation of simulation processes using scripting tools where appropriate.
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Cross-functional Engineering Collaboration
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Work closely with design, validation, and manufacturing teams to ensure simulation results are incorporated into design decisions.
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Provide technical input into design reviews, development meetings, and programme milestones.
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Documentation & Reporting
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Prepare technical reports summarising simulation results, design recommendations, and validation evidence.
Qualifications:
- Bachelor’s or Master’s degree in Mechanical Engineering, Automotive Engineering, Mechatronics, or a related engineering discipline.
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Additional training or certification in FEA, structural simulation, or advanced mechanical analysis is advantageous.
Essential skills:
- Strong expertise in Finite Element Method (FEM) and Finite Element Analysis (FEA).
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Proficiency with industry-standard FEA tools such as:
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ANSYS Workbench
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Altair HyperWorks
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Abaqus
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MSC Nastran or similar simulation software.
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Solid understanding of mechanics of materials, structural dynamics, and fatigue analysis.
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Ability to interpret complex simulation results and translate findings into design improvements.
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Strong analytical and problem-solving capabilities.
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Effective communication skills to collaborate with multidisciplinary engineering teams.
Desired skills:
- Knowledge of NVH simulation and drivetrain vibration analysis.
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Understanding of DFM, DFMEA, and automotive product development processes.
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Familiarity with CAD tools such as CATIA, NX, or similar 3D design platforms.
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Exposure to electric vehicle powertrain architectures and electromechanical integration.
Experience:
- Experience working in Automotive, Motorsport, or high-performance engineering environments is desirable.
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Demonstrated involvement in FEA-driven design or structural simulation projects.
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Experience supporting component development from concept through validation and production readiness.
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Experience working collaboratively with design, testing, and manufacturing teams in engineering development programmes.
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Experience conducting static, modal, thermal, and transient dynamic simulations.
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Experience analysing powertrain components such as engines, transmissions, gearboxes, or electric drive systems.
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Experience with Python or MATLAB scripting for simulation automation and data processing.
Benefits:
- Collaborative working environment – we stand shoulder to shoulder with our clients and our peers through good times and challenges
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We empower all passionate technology loving professionals by allowing them to expand their skills and take part in inspiring projects
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Expleo Academy - enables you to acquire and develop the right skills by delivering a suite of accredited training courses
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Competitive company benefits
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Always working as one team, our people are not afraid to think big and challenge the status quo
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As a Disability Confident Committed Employer we have committed to:
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Ensure our recruitment process is inclusive and accessible
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Communicating and promoting vacancies
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Offering an interview to disabled people who meet the minimum criteria for the job
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Anticipating and providing reasonable adjustments as required
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Supporting any existing employee who acquires a disability or long term health condition, enabling them to stay in work at least one activity that will make a difference for disabled people
“We are an equal opportunities employer and welcome applications from all suitably qualified persons regardless of their race, sex, disability, religion/belief, sexual orientation or age”.
We treat everyone fairly and equitably across the organisation, including providing any additional support and adjustments needed for everyone to thrive
