Senior CAE Engineer - Crash & Passive Safety

Job Description

Job Summary

Zenvo is a Danish hypercar manufacturer building some of the most extreme road cars in the world, in very limited numbers and with an uncompromising focus on performance, engineering and driver emotion.

As a small, fast-moving team, every engineer here has a direct impact on the finished car.

The Role

We're looking for a Senior CAE Engineer - Crash & Passive Safety to support the development of world-class vehicle safety performance across our vehicle programs. At Zenvo, safety engineering is about delivering exceptional occupant protection while enabling uncompromising vehicle performance, lightweight design and engineering innovation.

Working closely with our Safety Engineering team, you will be responsible for developing and executing crash simulation activities from concept through validation and homologation. You will play a key role in translating safety targets into robust engineering solutions using advanced CAE methods and close collaboration with Program Management, Vehicle Engineering, Homologation and external partners.

This is a hands-on technical role requiring expert-level CAE experience in LS-DYNA, ANSA and META, combined with extensive automotive crash simulation experience and a strong understanding of composite vehicle structures.

Key Responsibilities

• Execute and support vehicle crashworthiness and passive safety development throughout the full vehicle development cycle.
• Develop, maintain and improve LS-DYNA crash models for full vehicle, subsystem and component-level assessments.
• Perform crash and safety simulations covering frontal, side, rear, rollover and low-speed impact requirements.
• Work closely with the Safety Engineering team to evaluate vehicle performance against occupant protection targets, regulatory requirements and internal objectives.
• Drive the crash development of lightweight carbon-fibre and composite vehicle structures, balancing safety, weight, stiffness and manufacturing requirements.
• Develop and implement efficient modelling methodologies, standards and best practices using ANSA, META and LS-DYNA.
• Collaborate closely with Program Management to ensure crash and safety deliverables support program timing, gateway reviews and vehicle milestones.
• Partner with Engineering teams across body, chassis, powertrain, battery systems and vehicle integration to identify and resolve crash-related design issues.
• Support Homologation activities by providing simulation evidence, technical assessments and regulatory compliance documentation.
• Analyse crash test and component test results, correlate physical testing with simulation results and continuously improve model accuracy.
• Support restraint system integration and occupant protection assessments in collaboration with Safety Engineering and external suppliers.
• Define, review and assess crash-related supplier deliverables and simulation data.
• Communicate simulation results, technical risks and engineering recommendations to project stakeholders and management.
• Support the continuous development of Zenvo's crash simulation capability, processes and toolchain.

Qualifications

• Minimum 7 years of automotive crashworthiness and passive safety engineering experience.
• Proven experience leading vehicle crash development programs from concept to homologation.
• Expert-level proficiency with LS-DYNA for explicit crash simulation.
• Advanced experience with ANSA and META for pre-processing, model build, post-processing and reporting.
• Strong understanding of occupant safety, restraint systems and global crash regulations such as UN and FMVSS.
• Demonstrated experience developing crashworthy carbon-fibre composite and mixed-material vehicle structures.
• Experience correlating CAE results with physical crash testing.
• Degree in Mechanical Engineering, Aerospace Engineering or a related technical field.
• Fluent English.
• Willingness to travel to test facilities and homologation sites.

Application Process:

Zenvo is an equal opportunity employer committed to diversity and inclusion in the workplace.