Simulation Engineer

Alloyed is a venture-funded company consisting of more than 160 world-class metallurgists, mechanical/design engineers, and software developers working across offices in the UK, Japan, and Seattle. We specialize in developing advanced metal components for industries including consumer electronics, AR/VR, liquid cooling systems, and additive manufacturing (AM) applications. Our proprietary software packages leverage advanced machine learning and physical modelling to create innovative alloys, optimize processing techniques, and design high-performance, 3D-printed components.

We are seeking a highly skilled Simulation Engineer to support and advance our simulation-driven design activities, specifically targeting structural and thermal analysis of additive manufactured components. Your primary focus will include consumer electronics products, with particular emphasis on AR/VR systems and liquid cooling solutions. You will collaborate closely with cross-functional teams to validate simulation accuracy, optimize designs, and improve performance outcomes.

Location: Abingdon Business Park, Abingdon

Responsibilities:

• Conduct structural (FEA) and thermal simulations (CFD) to support the design and optimization of additive manufactured components and product assemblies using those components.
• Prepare and execute simulation campaigns, defining boundary conditions, materials properties, and performance metrics.
• Collaborate with design and production teams to refine simulation models.
• Define and execute experimental campaigns to validate simulations.
• Generate technical reports and present simulation findings, highlighting implications and recommendations for design enhancements.
• Develop simulation-driven strategies to solve complex design challenges in consumer electronic assemblies, particularly in AR/VR (both active and passive), and liquid cooling systems.
• Improve existing simulation workflows, developing custom methodologies and algorithms to enhance accuracy and efficiency.
• Maintain documentation standards, ensuring clarity and traceability of simulation models and results.

Essential:

• MSc with at least 2 years of industry experience or PhD in Mechanical Engineering, Aerospace Engineering, or a related discipline.
• Strong proficiency with implicit and explicit structural and thermo-fluid simulation tools (e.g., ANSYS Mechanical, ANSYS Fluent, Altair HyperWorks, Abaqus).
• Experience simulating complex, multi-part assemblies in both FEA (e.g. drop testing), and thermal performance (e.g. measuring heat dissipation).
• Ability to simplify real product assemblies to assemblies that can be simulated with minimal impact to fidelity and accuracy.
• Solid understanding of thermal management and structural optimization assemblies.
• Understanding of active and passive cooling systems and approaches to accurately simulate their performance.
• Creative problem-solving abilities with meticulous attention to detail.
• Excellent organizational and project management skills.
• Effective communication skills, capable of clearly conveying technical concepts to internal stakeholders and customers.

Desirable:

• Expertise with CAD software (e.g., SolidWorks, Autodesk Fusion).
• Experience with surface-based and topology optimization modelling.
• Experience with generative design.
• Good understanding of mechanical product assemblies.
• Solid understanding of consumer electronics, particularly thermal management and structural optimization of consumer electronics assemblies.
• Demonstrated experience in simulation for additive manufacturing processes (LPBF).
• Background in engineering consultancy or customer-focused engineering solutions.
• Knowledge of metal characterization and testing procedures relevant to additive manufacturing.

Compensation: A highly competitive remuneration package is offered, including salary, equity incentives, and opportunities for professional growth.

Application Process: Interested candidates should submit their CV, and a supporting statement clearly highlighting how they meet the selection criteria to jobs@alloyed.com. A portfolio demonstrating relevant design and engineering work is optional but desirable. All documents should be submitted as PDFs with your name and document type in the filename.