Sr CAE Engineer - Chassis

Hyundai-KIA America Technical Center, Inc.•Superior Township, MI

51d

About The Position

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.

Requirements

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.

Nice To Haves

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.

Responsibilities

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

Benefits

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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