Technical Specialist - CAE Mold Flow

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Product Development uses design thinking & user experience methods to deliver breakthrough products and services that delight our customers. We bring innovative, exciting, and sustainable ideas to life. We have opportunities around the world for you to contribute to advancements in autonomy, electrification, smart mobility technologies, and more!

In this position... 

Moldflow CAE Technical Specialist focuses on advanced injection molding simulation to optimize part and tool development for Exterior Systems, ensuring alignment with corporate requirements. The successful candidate will lead, perform, and audit Moldflow simulations, transforming models into high-fidelity finite element representations to accurately predict performance and identify cost-saving opportunities across all development stages.

Key responsibilities include problem-solving molding-related issues, authoring new design rules and acceptance criteria for molded materials, and providing critical technical support to D&R, PD Finance, Purchasing, and Cost Optimization teams. Furthermore, this position involves reviewing and validating supplier simulations, interpreting CAE and physical test results to develop feasible countermeasures, and establishing strong correlations between virtual and physical testing. Active participation in local and global forums to share emerging methodologies, teaching Moldflow courses, and maintaining a forward-looking mindset on new technologies are also essential aspects of this role.
 

What you'll do...

• Lead, perform, and audit advanced injection molding simulations to identify efficiency opportunities in part and tool development, ensuring alignment with ESOW/MSOW requirements.
• Lead problem solving for issues related to molding
• Improve or author new requirements and design rules and acceptance criteria for molded materials
• Execute and review Moldflow simulation analyses for exterior system components, delivering robust design insights and complete technical documentation across all development stages.
• Create, modify, and transform injection molding simulation models into high-fidelity finite element representations that accurately predict Exterior Systems performance, following corporate standards and procedures. Perform detailed audits of Moldflow models for accuracy and compliance.
• Support Ford D&R, PD Finance, Purchasing, and Cost Optimization teams by reviewing the complete ED&T mountain chart to validate assumptions, identify efficiency opportunities, and define costeffective simulation targets based on program and commodity design scope.
• Provide technical support to D&R teams during T0 and DCV events, ensuring that tool performance correlates with simulation predictions and meets signoff requirements.
• Participate in local and global forums to share emerging methodologies, new procedures, and innovative approaches to injection molding simulation.
• Support the ELD organization by teaching Moldflow courses as part of the Plastics Curriculum for PD, Purchasing, Finance, and GVT teams.
• Interpret Moldflow, CAE, and physical test results to develop feasible countermeasures that ensure compliance with system and component level requirements. Establish strong correlation between simulation and physical testing.
• Perform and audit injection molding simulations at a level of detail appropriate to each development milestone, ensuring efficiency and consistency with design output needs.
• Review and validate supplier injection molding simulations, ensuring Exterior Systems targets are met through a consistent DV plan based on DVM methodologies and aligned with corporate requirements.
• Collaborate with global CAE teams and physical testing groups to improve simulation methods and enhance correlation between virtual and physical results.
• Maintain a forward looking mindset by staying current with emerging technologies, tools, and best practices in injection molding simulation.

You'll have...

Minimum Requirements:

• BS in Engineering or a related field 
  • Engineering degree (Science Materials, Polymer Materials, Mechanical, Mechatronics, desirable) or related disciplines with coursework in Finite Element Methods.
• 8+ years - Strong ability to interpret injection molding reports and identify improvements in part design, tool design, and process parameters.
• Skilled at distinguishing high value simulation reports from those lacking technical rigor or sufficient