Sr. CAE Engineer – Durability Methods

At Polaris Inc., we have fun doing what we love by driving change and innovation. We empower employees to take on challenging assignments and roles with an elevated level of responsibility in our agile working environment. Our people make us who we are, and we create incredible products and experiences that empower us to THINK OUTSIDE. Position Overview: You will provide technical leadership in the development and advancement of durability engineering methods to support next-generation off-road vehicle design. In this role, you will lead the application of FEA-driven simulation techniques to improve predictive accuracy, efficiency, and consistency across engineering teams. You will collaborate with global stakeholders to standardize processes, integrate physical test data, and influence early-stage product development decisions. You will also mentor engineers and promote adoption of best practices and scalable methodologies. This role offers the opportunity to shape durability engineering approaches and drive meaningful impact on product performance and development effectiveness.

• Lead the development, validation, and deployment of advanced durability methods using commercial CAE and FEA tools.
• Drive innovation in FEA-based simulation approaches, including fatigue analysis, nonlinear simulation, transient response, and complex joint modeling.
• Identify gaps in current CAE workflows and establish standardized processes to support global engineering consistency.
• Define and implement modeling guidelines, load case strategies, and post-processing procedures to improve scalability and repeatability.
• Develop and standardize load generation approaches, durability events, and virtual use cases.
• Collaborate with MBD and test teams to improve integration of loading data and enhance simulation fidelity.
• Improve correlation between simulation models and physical test results through validation and method refinement.
• Develop and implement automation strategies to streamline CAE workflows using scripting tools.
• Apply durability methodologies early in vehicle architecture development to influence design decisions and performance targets.
• Provide technical leadership, mentorship, and subject matter expertise to engineering teams. Desired Competencies:
• Technical / Functional Expertise: You apply the required technical or professional knowledge to perform your role effectively and stay current within your area of expertise.
• Critical Thinking: You analyze information objectively, evaluate options, and apply sound judgment to solve problems and make informed decisions.
• Leadership: You inspire, guide, and empower others to achieve their best by setting clear direction, fostering trust, and creating an environment where people feel supported, motivated, and accountable for delivering results.

• Bachelor’s degree in Mechanical Engineering or a related field.
• Minimum of 6 years of experience in durability analysis, structural simulation, or CAE methods development with a focus on FEA-based approaches.
• Expertise with FEA tools such as Abaqus, ANSYS, OptiStruct, or similar platforms.
• Strong proficiency in fatigue analysis, nonlinear simulation, load case development, and structural durability.
• Experience developing or applying simulation methods to support engineering decision-making.
• Experience improving correlation between simulation results and physical test data.
• Experience with scripting and automation tools such as Python or TCL.
• Ability to work across global engineering teams and drive adoption of standardized processes and methodologies.
• Strong communication, interpersonal, and technical leadership skills.
• Familiarity with vehicle systems design and validation, particularly chassis, suspension, driveline, or structural systems.