FEM Simulation Engineer (Structural & Fatigue)

As a FEM Simulation Engineer at Ailit, you will define the structural backbone of our PowerPack - the swappable energy unit powering next-generation freight rail.

You will lead strength, fatigue, and durability simulations for heavy rail environments, ensuring our systems withstand extreme loads, vibration, and long-term operation across North American freight networks.

This is core engineering - building hardware that moves real 10000+ ton heavy trains.

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• Perform advanced FE-based structural and fatigue simulations for heavy rail applications
• Develop and validate models for welded steel structures under dynamic loading
• Calibrate simulation models using field data, rig testing, and vehicle measurements
• Analyze weld fatigue, bolted joints, and structural interfaces
• Automate and optimize simulation workflows
• Work closely with mechanical design, electrical, and test engineers to close the loop between simulation and reality
• Contribute to certification documentation and structural validation strategy

• Have held the title FEM Simulation Engineer (or equivalent)
• Have experience in heavy industry, rail, defense, automotive, or other high-load systems
• Hold a Master’s degree in solid mechanics, computational mechanics, mechanical engineering, or similar
• Have strong experience with tools such as Abaqus, Hyperworks, OptiStruct, Ansys, FEMFAT, or similar (Hyperworks is a plus)
• Understand weld behavior, fatigue, and structural durability in real-world environments
• Are comfortable working between CAD, simulation, and physical testing
• Write Python to automate and scale your work is a plus
• Care about getting hardware certified and deployed - not just modeled

Ailit is building the autonomous energy layer for next-generation freight rail: a swappable battery platform with intelligent energy optimization for existing locomotive fleets. This solves both range limitations and charging/grid constraints.

Our systems are built for heavy-haul deployment in North America and other industrial rail markets. We combine deep rail leadership with startup velocity and ambitious engineering culture.

Competitive salary based on seniority and equity upside for our ambitious ride.