Chassis CAE Engineer

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 to support the development, optimization, and validation of next-generation chassis and suspension systems. The ideal candidate should have an intensive experience in structural Finite Element simulations enabling robust simulation-driven decision‑making across early- and late-stage product development.

This role will work cross-functionally with the Chassis team—primarily—and collaborate with other domains such as Body Structures, Closures, Vehicle Dynamics, 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.

Job description:

• Perform chassis and suspension structural and fatigue FEA using ABAQUS and NASTRAN using any of the durability, static, dynamic, nonlinear, and fatigue analysis techniques.
• Analyze control arms, subframes, frames, suspension links, knuckles, crossmembers, bushings, and related systems under static, dynamic, and durability loading.
• Correlate simulation results with physical test data to improve model accuracy and prediction robustness.
• Generate technical documentation, reports, and recommendations to guide design decisions.
• Support Body structure, and NVH-related CAE activities.
• Participate in engineering reviews, presenting analysis results and design recommendations.
• Support R&D initiatives and innovation projects improving chassis performance, refinement, and robustness.
• Capture welds, joints, spot welds, hard‑points, and boundary conditions according to established chassis simulation guidelines.
• Guide physical test planning, develop test matrices, and correlate CAE predictions with test results using proving ground road load data acquisition and other relevant test inputs.
• Perform mechanical joint/fasteners 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.
• Ability to create and utilize programming tools such as MATLAB and Python.
• Travel up to 5% domestic and international.

• Educational Requirements:
  • Bachelor’s Degree in Mechanical Engineering, Electrical Engineering or a related field of study
  • Preferred:
    PhD/MSc in Mechanical Engineering or a related field of study
• Related Industry Experience Requirements:
  • 5+ years of Body Finite Element Structural CAE Simulations using ABAQUS and NASTRAN for Chassis.
  • 2+ years of experience leading engineers through automotive production work.
• Required Skills and Knowledge:
  • Expertise in technical report preparation experience.
  • Ability to work independently with minimum guidelines.
  • St…