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Salary: USD 120,000 - 151,000 / annual
Re:Build Optimation, part of Re:Build Manufacturing, is seeking a Principal Design and Simulation Engineer to lead structural, thermal, and fluid simulation efforts for industrial machinery and equipment. The company operates an advanced, end-to-end manufacturing platform serving aerospace and defense, electrification, medical, energy, and robotics sectors.
In this role, you will be a technical expert applying Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) expertise to solve complex engineering challenges, validate designs, and deliver reliable, high-performing manufacturing solutions. You'll work closely with mechanical design engineers, project teams, and customers to translate simulation results into practical design improvements.
Key responsibilities include:
- Lead structural, thermal, and fluid simulations (FEA/CFD) for industrial machinery projects
- Perform and validate simulations using SolidWorks Simulation, SolidWorks Flow Simulation, Ansys, and Ansys Fluent
- Partner with mechanical design engineers to define simulation requirements, boundary conditions, meshing strategies, and CAD model preparation
- Evaluate mechanical systems including structural weldments, piping, pressure vessels, rotating equipment, and automated machinery
- Translate simulation results into practical recommendations that improve equipment safety, reliability, and performance
- Develop simulation standards, validation methods, and best practices to improve analysis accuracy and consistency
- Review and approve engineering calculations, simulation reports, and technical documentation
- Mentor engineers, share technical knowledge, and guide project teams in applying simulation insights to design decisions
- Collaborate with customers and cross-functional teams to develop solutions and support project execution
- Contribute to project estimates, proposals, technical reviews, field assessments, and commissioning activities
- Support compliance with applicable engineering codes, safety standards, and regulatory requirements
Re:Build Optimation has nearly 40 years of experience in complex chemical process systems, with a multidisciplinary team of 70+ engineers, designers, and programmers, plus 150,000 square feet of fabrication space and over 70 skilled tradespeople. The company serves industries ranging from traditional and green energy to chemicals, pharmaceuticals, food & beverage, glass, and advanced manufacturing.
REQUIREMENTS:
- Bachelor's or master's degree in Mechanical Engineering or equivalent engineering discipline
- 10–15 years of relevant experience in industrial machinery, manufacturing, or capital equipment engineering, including significant FEA/CFD experience
- Proficiency in SolidWorks, including Simulation/FEA and Flow Simulation, with experience using Ansys and Ansys Fluent
- Strong understanding of simulation techniques, including meshing, boundary conditions, material properties, convergence, and validation
- Ability to collaborate with mechanical design engineers to prepare simulation-ready CAD models and improve designs
- Knowledge of mechanical engineering principles, fabrication methods, and industry codes such as ASME, API, and NFPA
- Experience defining technical requirements, estimating engineering costs, and supporting project delivery
- Strong communication, analytical, and problem-solving skills, with an interest in mentoring and developing others
- Commitment to safe engineering practices and continuous improvement
- Ability to work on-site in Rochester and/or Rush, NY, with travel as needed (typically less than 25%)
PREFERRED SKILLS:
- Professional Engineer (PE) license
- Experience with automated machinery, robotics, precision motion systems, web handling, piping, pressure vessels, or related mechanical systems
- Experience validating simulation results through physical testing
- Knowledge of fatigue analysis, vibration analysis, topology optimization, or thermal-fluid analysis
- Familiarity with advanced SolidWorks tools, AutoCAD, Creo/ProE, or similar software
- Experience with ISO 9001, Lean, Six Sigma, or continuous improvement practices
