Sr. Brake Systems Engineer

Sr. Brake Systems Engineer

Hyundai America Technical Center, Inc. (HATCI) is searching for a Senior Engineer for the Chassis Engineering Team II

The Team:

The Chassis Engineering Team II would oversee the design, development, and release efforts of the following disciplines: chassis mounts, vehicle braking systems, and vehicle driveline systems

The Position:

The Sr. Brake Systems Engineer would be a key technical leader, overseeing the complete brake system development lifecycle – from concept and CAD modeling through testing and production release, plus ensuring brake designs meet all performance targets, reliability, and safety regulations and are optimized for SUV, truck, and off-road use

What You Will Do:

• Lead Brake System Design and Development: Lead end-to-end design of brake systems and components (e.g., hydraulic boosters, calipers, rotors, pads, actuators) using CATIA V5 and develop robust mechanical layouts and CAD models that meet vehicle performance, packaging, and manufacturing requirements
• Simulation and Analysis: Perform and coordinate detailed engineering analysis (i.e., FEA, multi-body simulation, NVH studies, etc.) to predict brake performance, durability, and noise-vibration-harshness (NVH) characteristics and iterate designs based on simulation and test data to optimize stopping power and reliability
• Cross-functional Collaboration: Work closely with vehicle design, dynamics, controls, powertrain, and testing teams to define brake system requirements that align with vehicle performance and safety targets and coordinate with hardware and software groups (i.e., ABS/ESC controls and regenerative braking teams) to ensure seamless integration of brake functions
• Supplier and Manufacturing Coordination: Partner with suppliers and internal manufacturing to select components (e.g., calipers, masters, valves, etc.) and processes; ensure supplier designs meet Hyundai Motor Group (HMG)'s specifications and validate build and quality capabilities; manage design reviews, DFMEA, and cost targets in collaboration with procurement
• Validation and Testing: Define, support, and execute comprehensive test and validation plans for brakes, including hardware-in-the-loop, brake dynamometer, bench, and full-vehicle tests; lead prototype and durability testing in lab and real-world off-road conditions; analyze test data (e.g., performance curves, fade, pedal feel, braking distance, etc.) and drive design iterations to meet federal and international requirements and internal standards
• Technical Documentation: Create and maintain all project documentation, including 3D CAD models and 2D drawings (using CATIA V5), bills of materials (BOMs), specifications, test plans, and test and validation reports; present technical findings and design reviews to management and cross-functional teams for review 
• Failure Analysis and Continuous Improvement: Investigate any brake system issues or field failures; perform root-cause analysis and implement corrective actions; drive continuous improvement by capturing lessons learned and refining future designs; review IQS, VDS, JP Power, and Consumer Reports to support warranty and quality issues
• Leadership and Mentorship: Act as a technical lead within the chassis/brake team; mentor and train junior engineers, providing guidance on engineering best practices and project management; demonstrate leadership by setting high standards for quality and innovation and by fostering a collaborative team atmosphere
• Travel up to 20% of the time, both domestically and internationally

What You Will Bring to the Role:

• Basic Qualifications:
  • Bachelor's degree in mechanical, automotive, or a related field of engineering
  • 8-10 years of chassis or brake design experience
  • Proficiency with 3D modeling, assemblies, and 2D drawing generation via CATIA V5
  • Experience with CAD data management and revision control
  • Deep understanding of brake system architectures and components for SUVs, trucks, and off-road vehicles, including hydraulic service brakes, vacuum or electro-hydraulic boosters, and foundation brake elements (i.e., calipers, rotors, and linings)
  • Knowledge of U.S. brake safety regulations (i.e., FMVSS) and relevant SAE standards. Familiarity with FMVSS 105/135 (brake requirements) and SAE test protocols is essential, as one would need to ensure designs comply with all applicable vehicle safety regulations and certification requirements
  • Demonstrated ability to interpret test data, perform data-driven design decisions, and apply engineering analysis
  • Flexibility with program and process changes, as Hyundai/Kia/Genesis is willing to make late changes to satisfy customer needs
  • Good written, oral, interpersonal, and leadership skills
  • Proficiency in Microsoft programs, such as Excel, Outlook, PowerPoint, and Word
  • Excellent time management, self-management, and organization skills
  • Ability to remain current with new technologies and best practices
  • Willingness to attend training, workshops, or conferences to enhance skills
  • Ability to diagnose and resolve complex, section-related issues 
  • Valid Driver's License and a satisfactory driving record

• Preferred Qualifications:
  • Master's degree in mechanical, automotive, or a related field of engineering
  • Experience working on electric or hybrid vehicle brake systems (e.g., integration with regenerative braking or electromechanical brakes).
  • Familiarity with EVs, pickup trucks, SUVs, and off-road vehicles and their specific brake durability/fade requirements (e.g., severe environments, water fording, etc.)
  • Experience with advanced systems, like electric parking brakes, regenerative braking, and brake-by-wire
  • Understanding of ABS (anti-lock) and ESC (electronic stability) systems and their integration 
  • Experience performing advanced suspension modeling, simulations, and optimization via CAE tools (e.g., ANSYS, Nastran, MATLAB/Simulink, etc.)
  • In-depth understanding of vehicle ride & handling, off-road performance, and NVH considerations specific to heavy-duty trucks and SUVs
  • Knowledge of solid axle and independent suspension systems in off-road conditions
  • Familiarity with CATIA V6 and PDM (i.e., ENOVIA V6) or Windchill PLM systems
  • Professional Engineer (PE) license or Six Sigma certification

What Hyundai Can Offer You:

• 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
• Hybrid Work Schedule
• 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

Other Details:

• Candidates applying for positions with Hyundai KIA must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.
  • HATCI is an Equal Opportunity Employer including Disabled and Veteran. VEVRM Federal contractor.