Chassis CAE Engineer

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 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. WHAT YOU WILL DO 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 WHAT YOU WILL BRING TO THE ROLE 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. Strong oral and verbal communication skills. Knowledge of automotive suspension system and vehicle dynamics. Additional Requirements: Demonstrated history of patent creation and academic publications will be useful.