Sr CAE Engineer - Body

Hyundai Motor Company-posted 21 days ago
Full-time • Mid Level
Ypsilanti Charter Township, MI
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Sr CAE Engineer – BodyWHAT YOU WILL DOThe Advanced Engineering Lab at Hyundai-Kia America Technical Center, Inc. (HATCI) conducts advanced technology research and development to support the creation of world-class vehicles. The team is seeking a motivated Senior CAE Engineer to perform CAE analysis for body structures and closures components at both the component and system levels. This role will also involve close collaboration with cross-functional teams, both domestically and internationally, to support the development of future Hyundai, Kia, and Genesis vehicles.HOW WILL YOU MAKE AN IMPACT

  • Prepare and modify CAE models from CAD using HyperMesh, including creation of 1D, 2D shell, and 3D solid meshes for BIW and closures.
  • Build complete CAE models from scratch, perform model check-runs, and ensure model quality and compliance with simulation standards.
  • Conduct structural stiffness, strength, durability, static, dynamic, nonlinear, and fatigue analyses for body structures.
  • Develop and execute analysis plans for subsystem-level assessments of BIW structures, closures, top hats, underbody systems, dash structures, front-end structures etc.
  • Capture welds, joints, spot welds, hard-points, and boundary conditions according to established body structure and chassis simulation guidelines.
  • Apply appropriate modeling techniques for stiffness, linear/nonlinear strength, fatigue, and welded-joint behavior, including incorporation of manufacturing effects.
  • Guide physical test planning, develop test matrices, and correlate CAE predictions with test results using CPG, RLDA, and other relevant test inputs.
  • Perform mechanical joint strength simulations and evaluate load transfer and failure risks.
  • Use advanced fatigue prediction tools (e.g., nCode, FeSafe) for seam weld, spot welds and base metal fatigue evaluation using proper load histories.
  • Apply modal transient fatigue methods to improve fatigue life prediction under dynamic loading conditions.
  • Demonstrate strong understanding of solid mechanics and ensure accurate correlation between CAE simulations and physical tests.
  • Collaborate with design, materials, supplier, attributes, and MBD teams across domestic and overseas groups to support robust design development.
  • Lead multiple CAE-intensive projects simultaneously, delivering high-quality results that drive design decisions.
  • Participate in weekly CAE meetings to coordinate model development and project progress.
  • Create technical reports, documentation, and presentations per established guidelines and present results to engineering and leadership teams.
  • Develop new analytical methods and virtual validation procedures to enhance prediction accuracy and reduce physical testing.
  • Conduct data-driven root-cause analysis of field or test failures and develop validated countermeasures.
  • Maintain and improve best practices, design standards, test procedures, and technical specifications.
  • Travel up to 5% domestic and international
  • 5+ years of experience in using CAE Body using Abaqus and Nastran.
  • 5+ years of experience in using Pre & Post CAE modeling software, e.g., Ansa and HyperWorks.
  • Technical report preparation experience.
  • Ability to work independently with minimum guidelines.
  • Strong oral and verbal communication skills.
  • Master’s degree in mechanical engineering or related discipline.
  • Hands-on experience on Chassis CAE analysis for automotive.
  • Zero-dollar Employee Premiums on Medical, Dental, and Vision for You and Your Family
  • 100% Employer-paid Disability and Life Insurance
  • Generous Paid Time Off, Including Vacation, Sick, and Abundant Holidays
  • Competitive Salaries
  • A Global Environment that Fosters Diversity
  • Retirement Savings and Planning Benefits
  • Access to Health Savings Accounts and Flexible Spending Accounts
  • Flexible Work Hours
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