Senior Structural Hardware Engineer – ECU at General Motors LLC — Warren, MI

Job Description

General Motors is at the forefront of the transformation of automotive with the electrification of our portfolio and the development of leading-edge central compute and autonomous capabilities. Our ECU Mechanical & Structural Design team is a dynamic, high-energy, and innovative group focused on developing robust mechanical architectures for next-generation ECUs (Electronic Control Units). The team is responsible for structural design, analysis, and validation of new ECU designs using engineering fundamentals, CAD, and CAE, while also reviewing and approving production design changes.

We are seeking a high-performing Structural CAE Hardware Engineer interested in leading the in-house development of electronics design. You will be responsible for the structural analysis, durability, and validation of electrical controllers and supporting hardware for our next-generation SDV (Software Defined Vehicle) architecture. This role requires strong collaboration with cross-functional and external partners.

What You’ll Do

• Translate CTQs / vehicle requirements into structural requirements and design constraints (vibration, shock, crash loads, mounting conditions, environmental exposure, etc.)
• Develop and execute structural simulation models (linear/nonlinear FEA) to assess strength, stiffness, fatigue, and durability of ECU components and assemblies
• Perform analyses for vibration, modal response, random vibration, mechanical shock, and mechanical integrity under various loading conditions
• Evaluate and optimize designs for weight, stiffness, durability, and manufacturability
• Support material selection, joint design, fasteners, and structural interfaces to ensure robust performance
• Work with cross-functional teams (design, EE, manufacturing) to implement structural design improvements
• Develop validation plans and correlate CAE results with physical test data (lab and vehicle level)
• Provide structural inputs to DFMEA, DRBFM, and design reviews; clearly quantify risks, failure modes, and mitigations
• Present analysis results, trade studies, and recommendations at PDTs, design reviews, and leadership updates

• BS in Mechanical Engineering (or related discipline) with strong focus on solid mechanics and structural analysis
• 5+ years of experience in structural analysis/design of electronic enclosures or similar systems (ECUs, automotive components, aerospace, or industrial products)
• Hands-on experience with CAE/FEA tools (e.g., Abaqus, ANSYS Mechanical, Nastran, HyperMesh, or equivalent) and data analysis tools (e.g., MATLAB, Python, or similar)

Strong understanding of:

• Stress, strain, deformation, and failure theories
• Linear and nonlinear FEA, contact modeling, and material modeling
• Fatigue, durability, and vibration analysis (modal, harmonic, random vibration)
• Bolted joints, welds, snap fits, and other mechanical connections
• Material behavior (metals, plastics, composites) under thermal and mechanical loading
• Practical experience correlating CAE models to physical test results (vibration tables, shock testing, durability testing)
• Ability to interpret system loads and boundary conditions and collaborate closely with design and test teams
• Strong communication skills; able to present complex structural analyses clearly to both technical and non-technical stakeholders
• Demonstrated ability to work across cross-functional and global teams and manage multiple programs in parallel

What Will Give You a Competitive Edge (Preferred):

• MS or PhD in Mechanical Engineering (Structures/Mechanics) or related field
• Automotive experience with vibration, durability, and environmental standards
• Experience with ECU housing design, packaging, and mechanical integration
• Familiarity with manufacturing processes (castings, injection molding, sheet metal, machining) and their structural implications
• Experience integrating structural design into DFMEA/DRBFM/DFx processes
• Knowledge of multi-physics interactions (structural + thermal coupling)
• Prior work with ECU designs

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