Senior Additive Simulation Engineer

About the Team: 

Relativity Space pioneered large-scale additive manufacturing with our Terran 1 rocket, the largest 3D-printed object to fly. Now a distinct business unit within Relativity, Horizon Manufacturing Technologies is advancing next-generation manufacturing for aerospace and beyond. The team operates at the frontier of manufacturing innovation, where creativity meets capability. This is an environment where cutting-edge R&D is put into production, industrializing advanced manufacturing capabilities to solve customer problems. You’ll work alongside welders, robotics engineers, data scientists, and systems engineers at the intersection of hardware and software, creating an end-to-end additive manufacturing platform that serves a wide variety of applications. From exploring new materials to unlocking faster print speeds, to designing complex, organic geometries that can’t be built any other way, it’s high-impact work that sets the foundation for the future of advanced manufacturing

About the Role:

• Develop, implement and validate next-generation simulation frameworks that leverage physics-based and data-driven approaches to accelerate Multiphysics analyses for metal additive manufacturing (AM) processes
• Integrate physics-informed or reduced-order models into existing FEA/CFD workflows (e.g., Abaqus, Flow-3D) to enhance speed and scalability
• Build and calibrate surrogate models that accurately approximate high-fidelity simulations while maintaining minimal accuracy loss
• Analyze and balance trade-offs among model fidelity, computational efficiency, and generalization performance for different applications
• Evaluate and deploy AI‑driven simulation frameworks (e.g., Altair PhysicsAI, Ansys SimAI) to accelerate thermomechanical and fluid simulations, model calibration, and design optimization
• Support development of automated workflows for parametric studies, uncertainty quantification, and sensitivity analyses using scripting languages and high-performance computing
• Prepare detailed documentation, reports, and presentations to communicate model findings to promote adoption of advanced simulation methodologies
• Stay current with the latest advancements in AM process modeling, simulation methodologies, and additive manufacturing process control

About You:

• BS or higher in Aerospace Engineering, Mechanical Engineering, Materials Science, Welding Engineering, Data Science, or a related field
• 5+ years relevant experience
• Strong understanding of heat transfer, mechanics, finite element methods, and numerical modeling for structural and Multiphysics applications
• Hands-on experience with multiphysics analyses involving solid and/or fluid mechanics using tools such as ABAQUS, ANSYS, Flow3D, COMSOL or equivalent, including setup, analysis and interpretation of results
• Experience with automated and dynamic meshing techniques
• Proficient in Python programming, with experience in numerical and scientific computing libraries such as NumPy, SciPy and related tools
• Experience with data preprocessing, model training, and validation workflows, including handling simulation datasets and building data pipelines for AI/ML applications
• Excellent communication skills, with ability to convey complex technical concepts effectively to interdisciplinary teams and stakeholders

Nice to haves but not required:  

• PhD in Aerospace Engineering, Mechanical Engineering, Materials Science, Welding Engineering, Data Science, or a related field, with a strong focus on computational modeling or AI applications
• 8+ years relevant experience
• Background in advanced machine learning, reduced-order modeling, or adaptive remeshing, with experience in integrating these approaches into physics-based modeling and simulation workflows
• Proven ability to translate research concepts into practical, deployable solutions in engineering or simulation contexts
• Experience working with version control systems (e.g. git)