Senior Development Engineer - Finite Element Analysis (FEA) Engineer

Make your mark at the world's largest HVAC company

Daikin Applied is seeking a Senior Finite Element Analysis (FEA) Development Engineer. The Senior FEA Development Engineer will spearhead the development and implementation of advanced simulation methodologies to support the design and optimization of commercial HVAC products. This position requires a robust background in structural and solid mechanics, with specialized expertise in both heavy welded structures and lightweight sheet metal assemblies.

The ideal candidate will bring extensive experience in analyzing structural load conditions and a deep understanding of failure mechanisms, including static, dynamic, and fatigue-related failures. A strong knowledge of manufacturing processes and design for manufacturability (DFM) is essential, along with proficiency in FEA tools such as ANSYS. This role also involves mentoring fellow FEA engineers and fostering a collaborative, growth-oriented team culture. The Sr. FEA Development Engineer will promote open technical dialogue, strengthen team cohesion, and actively support the professional development of team members. Come be a part of an exciting journey at Daikin Applied, where innovation and excellence drive our every endeavor!

Location: Plymouth, MN - Hybrid

What you will do:

• Lead and mentor the structural simulation team by providing expert technical guidance in simulation methodologies, fostering collaboration, and ensuring alignment with best practices in digital modeling and structural analysis
• Identify simulation gaps in the structural design process and develop simulation methodologies to speed up product development
• Maintain and develop standardized modeling practices, templates, and libraries for structural simulations
• Create HVAC system simulation models by cleaning 3D geometries, generating meshes, and applying boundary and initial conditions, following established procedures or innovating new methodologies in collaboration with cross-functional teams
• Perform detailed FEA simulations to evaluate the structural integrity and performance of HVAC components and systems
• Analyze results to identify potential failure modes and recommend design improvements
• Generate detailed technical reports and presentations summarizing simulation results, design recommendations, and risk assessments
• Support product development through simulation-driven design, validation, and optimization
• Collaborate closely with design, manufacturing, and testing teams to ensure robust and manufacturable solutions
• Assist in establishing structural test plans and collaborate with internal test labs to support experimental data collection for model validation
• Ensure compliance with company safety policies and applicable regulatory standards in all analyses and design recommendations

What's in it for you:

• Medical/Dental/Vision coverage, PTO, 401K match, support for community involvement and much more
• The ability to make an impact and shape your career with a company that is passionate about growth
• The support of an organization that believes it is vital to include and engage diverse people, perspectives, and ideas to achieve our best

Minimum Qualifications:

• Bachelor's degree in Mechanical Engineering or a related field
• 6+ years of experience in FEA
• Proficiency with leading FEA tools such as ANSYS, Abaqus, Hypermesh and Python Scripting
• Strong expertise in NVH simulation techniques, including modal analysis, frequency response, acoustic analysis, and vibration isolation
• In-depth understanding of mechanical design principles, materials behavior, and fatigue analysis
• Experience correlating simulation results to physical testing data and refining models for accuracy
• Strong analytical skills with the ability to interpret complex data and provide actionable insights
• Excellent verbal and written communication skills, capable of presenting technical content to both engineering and non-engineering audiences
• Proficiency in Microsoft Office and report writing tools
• Ability to manage multiple projects and priorities in a fast-paced environment
• Work visa sponsorship is not available for this position

Preferred Qualifications:

• Master's degree in Mechanical Engineering or a related field
• Experience in HVAC product development or other mechanical systems with significant structures and vibration performance requirements
• Familiarity with experimental structural testing techniques and equipment (accelerometers, microphones, data acquisition systems)
• Knowledge of ASME Section VIII, Division 2, Part 5 - Design by Analysis, particularly in applying elastic and elastic-plastic analysis methods to ensure structural integrity and code compliance in pressure-retaining components
• Knowledge of statistical analysis methods, including DOE and Six Sigma principles
• Exposure to simulation governance frameworks and model lifecycle management
• Familiarity with AI/ML techniques as applied to FEA for surrogate modeling, design space exploration, and optimization
• Experience with Multi-Domain Optimization software (modeFrontier, optiSLang, etc.) and cross-physics simulation integration
• Understanding of thermal-structural coupling effects and simulation methods to predict performance under combined thermal and mechanical loads
• Experience with Agile development processes
• Familiarity with ISO and ASHRAE standards related to vibration and noise
• Experience with computer modeling software (e.g., AFT Impulse, CAESAR II, BOSpulse) to simulate acoustic scenarios and predict sound quality and piping pulsation

Benefits:

Daikin Applied offers the following benefits for this position, subject to applicable eligibility requirements:

• Multiple medical insurance plan options + dental and vision insurance
• 401K retirement plan with employer contributions matching 100% of the first 3% of employee contributions and 50% on the next 2% of employee contributions
• Company-provided life insurance + optional employee-paid voluntary life insurance, dependent life coverage, and voluntary accident coverage
• Short-term and long-term disability
• 3 weeks of paid time off for new employees + 11 company-paid holidays
• Vacation accrues on a monthly basis, unless applicable federal, state, and local law requires a faster accrual
• Paid sick time in accordance with the federal, state, and local laws
• Paid parental leave and tuition reimbursement after 6 months of continuous service

The typical annual base salary for this position ranges from $90,000-$183,200 in Minnesota + 10% bonus. The range displayed represents the pay range for all positions in the job grade which this position falls. Individual base pay will depend on a wide range of factors including your skills, qualifications, experience, and location.

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