FEA Analyst Mettle Ops Madison Heights, MI Job Details Full-time 13 hours ago Qualifications Thermal analysis Stress testing simulations Technical engineering Defect resolution root cause analysis Data analysis reporting Engineering phase involvement Verification (System development task) Performance testing in mechanical engineering Technical documentation Defect analysis Fatigue analysis Technical report writing Collaboration with product development teams Research report preparation Engineering research Mentoring Structural modeling Document review Technical research projects Solid mechanics FEA Collaboration with manufacturing teams Engineering product development Simulation tools Technical troubleshooting support Vibration analysis Mechanical design optimization Senior level Structural systems Research findings presentation Full Job Description Purpose The FEA Analyst is responsible for performing advanced engineering analysis using finite element analysis (FEA) and simulation techniques to support the design, development, evaluation, and validation of mechanical systems, structures, and components. This position independently develops and executes structural, thermal, and dynamic analyses to evaluate product performance, safety, reliability, and durability. The FEA Analyst works closely with design engineers, engineering leadership, and program personnel to identify engineering risks, develop simulation models, interpret results, and provide recommendations that support design decisions and product improvements. The position may support government and defense programs by providing engineering analysis for product development, qualification, testing, and contract deliverables. The successful candidate will have strong technical judgment, experience with complex engineering problems, and the ability to clearly communicate technical findings to both engineering and management audiences. Tasks Develop, execute, and document finite element analyses for mechanical components, assemblies, structures, and systems. Perform structural, thermal, dynamic, vibration, fatigue, and other applicable engineering analyses. Develop appropriate simulation methodologies based on product requirements, loading conditions, material properties, boundary conditions, and intended operating environments. Build, modify, and validate detailed FEA models using applicable engineering software. Evaluate stresses, strains, deformation, fatigue life, vibration response, thermal performance, and other relevant performance characteristics. Interpret analysis results and provide technically sound recommendations for design improvements, risk reduction, and product optimization. Work directly with design engineers to evaluate proposed designs and identify potential structural, material, performance, and reliability concerns. Provide technical input during design reviews, development activities, troubleshooting efforts, and engineering decision-making. Validate analytical models and results through comparison with physical test data, engineering calculations, empirical data, and other appropriate methods. Establish appropriate modeling assumptions, analysis methods, mesh strategies, loading conditions, and acceptance criteria. Identify limitations and potential sources of error within analysis models and clearly communicate their impact on results. Perform root-cause analysis and simulation-based troubleshooting of engineering and product performance issues. Evaluate materials, structural configurations, joints, interfaces, and other design features to determine expected performance and failure modes. Support product development, qualification, verification, and validation activities through engineering analysis. Prepare detailed technical reports documenting analysis methodology, assumptions, inputs, results, conclusions, and recommendations. Review engineering analysis performed by other team members for technical accuracy, completeness, and compliance with applicable requirements. Maintain accurate and organized records of analysis models, assumptions, inputs, outputs, results, and supporting calculations. Ensure analysis activities comply with applicable engineering standards, specifications, customer requirements, and program requirements. Support government and defense contract deliverables requiring engineering analysis, technical reporting, and supporting documentation. Coordinate with engineering, program management, manufacturing, testing, and other technical teams to resolve engineering issues and support program objectives. Provide technical guidance and knowledge sharing to less-experienced engineers and analysts. Research and implement improved analysis techniques, modeling methodologies, and engineering tools as appropriate. Assist with additional engineering analysis, development, and technical support activities as required.