Sr CAE Engineer - Chassis

Hyundai Motor Company-posted 21 days ago
Full-time • Senior
Ypsilanti Charter Township, MI
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The 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. We are seeking a highly skilled Chassis FEA Engineer with Multi-Body Dynamics experience to support the development, optimization, and validation of next-generation chassis and suspension systems. The ideal candidate brings a rare combination of structural FEA expertise and multi-body dynamics modeling capabilities enabling robust simulation-driven decision-making across early- and late-stage product development. This role will work cross-functionally with Chassis team-primarily and collaborate with other domains such as, Vehicle Dynamics, CAE, Controls, and NVH teams to deliver high-fidelity analysis, correlation, and simulation tools that improve ride, handling, durability, and system performance. 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.

  • Perform chassis and suspension structural, fatigue, and vibration FEA using ANSYS, NASTRAN, LS-DYNA, or equivalent.
  • Analyze control arms, subframes, suspension links, knuckles, crossmembers, bushings, and related systems under static, dynamic, and durability loading.
  • Develop FEA models, boundary conditions, load cases, and material definitions aligned with DVP&R requirements.
  • Correlate simulation results with physical test data to improve model accuracy and prediction robustness.
  • Generate technical documentation, reports, and recommendations to guide design decisions.
  • Build and validate full-vehicle and subsystem MBD models (ADAMS/Car, CarSim, AMESIM, or equivalent).
  • Perform kinematics-compliance (K&C), ride, handling, and durability event simulations.
  • Integrate frequency- and amplitude-dependent bushing models into chassis simulations.
  • Support chassis and driveline dynamics investigations, including traction control, suspension response, and NVH-related dynamics.
  • Develop custom driver models, road inputs, and dynamic events for simulation.
  • Partner with design, CAE, NVH, and vehicle dynamics teams to drive simulation-informed design decisions.
  • Participate in engineering reviews, presenting analysis results and design recommendations.
  • Support R&D initiatives and innovation projects improving chassis performance, refinement, and robustness.
  • Travel up to 5% domestic and international
  • Ph.D. or Master’s in Mechanical Engineering, Mechatronics, Vehicle Dynamics, or related field.
  • 5+ years of experience in chassis simulation, vehicle dynamics or multi-body modeling.
  • Strong proficiency in: FEA Tools: ABAQUS, NASTRAN, LS-DYNA MBD Tools: ADAMS/Car, CarSim, AMESIM Control Tools: MATLAB/Simulink Programming: Python, C/C++, Visual Basic
  • Experience with fatigue analysis, vibrations, and durability correlation.
  • Hands-on modeling of chassis/suspension and driveline systems.
  • Excellent analytical, documentation, and communication skills.
  • Experience with DFSS, DVP&R, parameter identification, or vehicle-level correlation.
  • Prior experience in OEM or Tier-1 vehicle development.
  • Knowledge of semi-active damping, MR damper modeling, or differential braking control.
  • Familiarity with NVH integration and system harmonization.
  • 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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