Sr. FRT & RR Suspension Engineer

Sr. FRT & RR Suspension Engineer

Hyundai America Technical Center, Inc. (HATCI) is looking for a Senior Engineer to join the Chassis Engineering Design Team/Department

The Team:

Chassis Engineering Design is a collaborative and innovation-driven team at a leading automotive company. The Chassis Engineering Design Team values open communication, continuous learning, and a hands-on approach. Additionally, the Chassis Engineering Design Team fosters a culture where senior engineers guide less experienced colleagues, share knowledge freely, and work together to solve complex engineering challenges. The team is committed to delivering high-quality, safe, and reliable Chassis systems, encouraging creative problem-solving and ownership at all levels. As part of the Chassis Engineering Design Team, one would work closely with a diverse group of designers, testers, and manufacturing engineers in an environment that rewards initiative, technical excellence, and professional growth.

The Position:

The Sr. FRT (front) & RR (rear) Suspension Engineer would lead design, development, and validation-related efforts concerning front and rear systems for U.S. SUV, pickup truck, and off-road vehicles to create a robust, high-performance suspension architecture. Additionally, one would work closely with cross-functional teams to ensure seamless integration, meet customer requirements, and achieve durability and reliability goals. 

What You Will Do:

• Lead Suspension Design: Drive end-to-end design of front and rear suspension components (e.g., control arms, springs, dampers, linkages, subframes, bushings, etc.) using CATIA V5. Generate detailed 3D models and 2D drawings and oversee CAD release for prototyping and production. Some CATIA V5 training would be available in-house.
• Mechanical Analysis: Coordinate FEA and kinematic/dynamic analyses with CAE groups/teams to ensure designs meet strength, stiffness, durability, and ride/handling targets. Analyze loads (i.e., static, dynamic, and fatigue) and iterate designs for weight, cost, and performance.
• Concept Development: Develop and document suspension concepts and packaging layouts, considering vehicle geometry, articulation, ground clearance, steering geometry, and off-road requirements. Ensure concepts align with project requirements and standards.
• Validation Planning and Testing: Define, support, and execute validation plans for suspension systems by aiding in test plan creation efforts, supporting prototype builds, and conducting bench and full-vehicle tests (e.g., durability, NVH, ride comfort, handling, off-road performance, etc.). Analyze the correlation between test data and simulation results and follow requests for design refinements (as needed).
• Supplier Coordination: Collaborate with suppliers concerning the design and development of suspension components. Provide technical direction and review supplier CAD models and drawings. Manage the supplier design review process and ensure supplier deliverables meet specifications and quality standards.
• Design Review and Documentation: Lead and participate in design reviews, DFMEA (Design Failure Mode and Effects Analysis)/PFMEA (Process Failure Mode and Effects Analysis) sessions, and design-for-manufacturing discussions. Prepare and maintain engineering documents (e.g., specifications, test reports, control plans, etc.) in adherence to and compliance with industry and regulatory standards.
• Documentation and CAD Modeling: Create and maintain detailed engineering documentation. Develop 3D models and 2D drawings in CATIA V5 for all components and assemblies (including applying GD&T as needed). Author and update technical specifications, DFMEAs, design review materials, and engineering reports to support program milestones and production readiness.
• Problem Solving and Continuous Improvement: Investigate and resolve engineering issues during development and support after-production launch issues (if requested). Implement corrective actions and drive continuous improvement efforts of suspension designs and development processes. Review IQS, VDS, JP Power, and Consumer Reports to support warranty and quality issues.
• Cross-Functional Collaboration: Work closely with manufacturing, quality, and product engineering teams to ensure designs are feasible for production and service. Participate and support in APQP (Advanced Product Quality Planning)/PPAP (Production Part Approval Process)-type processes to support vehicle program launches.
• Leadership and Mentorship: Mentor junior engineers on best practices and facilitate on-the-job learning
• Travel: 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 engineering, automotive engineering, or a related field
  • 7+ years of professional experience in chassis and suspension design, with a focus on front and rear suspension systems
    • Experience specifically with pickup trucks, SUVs, or off-road vehicles is highly preferred
  • Experience working on electric or hybrid vehicle suspension systems.
    • Prior experience with pick-up trucks, SUVs, or off-road vehicles and knowledge of their specific suspension systems, durability, set-up, articulation, etc., is advantageous
  • In-depth understanding of vehicle ride and handling, off-road performance, and NVH considerations specific to heavy-duty trucks and SUVs
  • Good working knowledge of vehicle body and NVH performance
  • Knowledge of solid axle and independent suspension systems in off-road conditions
  • Proficiency in CATIA V5
    • Familiarity with other CAD software (e.g., CATIA V6, NX, Solidworks, etc.) is beneficial
  • Experience using engineering tools to create and modify 2D and 3D drawings
  • Familiarity with PDM (e.g., ENOVIA V6) or Windchill PLM systems
  • Hands-on experience with mechanical analysis (i.e., FEA and analytical calculations) and suspension kinematics
  • Experience planning and executing vehicle or component tests (e.g., durability rigs, track testing, and NVH evaluations)
  • Knowledge of mechanical, industrial, or manufacturing engineering design and processes
  • Knowledge of tooling design variables and processes, along with related materials
  • Innovative thinking and proactive approaches to the technical direction of chassis components
  • Ability to explain technical topics to both technical and non-technical stakeholders
  • Adept in Microsoft programs, such as Excel, Outlook, PowerPoint, and Word
    • An ability to prepare reports/spreadsheets (when needed) to support project-related work
  • Flexibility with program and process changes, as Hyundai/Kia/Genesis is willing to make late changes to satisfy customer needs
  • Excellent time management, self-management, and organization skills
  • Strong written, oral, interpersonal, and leadership skills
  • Strong problem-solving skills
    • An ability to diagnose complex issues (e.g., failure analysis) and develop robust solutions under tight timelines and in cooperation with adjacent teams
  • Willingness to attend training sessions, workshops, or conferences to enhance skills and knowledge
  • Valid Driver's License and a satisfactory driving record

• Preferred Qualifications:
  • Master’s degree in mechanical engineering, automotive engineering, or a related field
  • Proficiency in utilizing CAE tools (e.g., ANSYS, Nastran, and MATLAB/Simulink) for advanced suspension modeling, dynamic simulations, and/or product optimization
  • Professional Engineer (PE) license or Six Sigma certification
  • Experience with vehicle program launches (from concept to production)
  • Project management experience

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
• 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. VEVRAA Federal contractor.