Sr. Chassis Driveline Engineer

Sr. Chassis Driveline 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. Chassis Driveline Engineer would lead design, development, and validation-related efforts concerning chassis driveline systems for U.S. SUV, pickup truck, and off-road vehicles to create a robust, high-performance driveline 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:

• Driveline Design and Development: Lead the engineering of driveline systems and components for 4WD and AWD vehicles, including transfer cases, power transfer units, and related mechanisms, to achieve performance and reliability targets
• Axles and Shaft Components: Design and develop axle assemblies and shaft components (e.g., solid rear axles, front/rear half-shafts, prop shafts, and driveshafts), ensuring they can withstand high-torque loads and off-road conditions while meeting weight and durability goals
• Differentials and Torque Management: Engineer advanced differential systems (i.e., front and rear), including limited-slip units, torque-vectoring differentials, and electronic-locking differentials, to optimize traction, handling, and stability for both on-road and extreme off-road usage
• Validation and Testing: Define, support, and execute comprehensive DVP&R (Design Verification Plan & Report) test plans for driveline components. Support bench tests, dynamometer tests, and vehicle field tests (on-road and off-road) to validate performance, durability, and NVH characteristics. Analyze test data and drive iterative design improvements based on results.
• Problem Solving: Monitor and troubleshoot driveline-related issues throughout the development cycle. Support root cause analysis for any failures or performance gaps (using techniques such as 5-Whys, Fishbone, etc.) and implement effective design or process changes to resolve issues promptly.
• Cross-Functional Collaboration: Work closely with cross-functional teams – including Vehicle Dynamics, Suspension, Powertrain, NVH, Manufacturing, and Quality – to ensure seamless integration of driveline systems into Hyundai, Kia, and Genesis vehicles. Coordinate packaging studies, interfaces, and systems integration to avoid conflicts and achieve performance objectives.
• Supplier Coordination: Liaise with OEM and Tier 1 suppliers for driveline components. Review and validate supplier designs or design-related changes, ensuring they meet all specifications and quality standards. Oversee supplier development activities and support the sourcing and manufacturing process for driveline parts.
• Standards and Compliance: Ensure all designs comply with relevant regulatory and industry standards, including Federal Motor Vehicle Safety Standards (FMVSS) and applicable SAE standards for chassis and driveline systems. Incorporate these requirements into the design specifications and validation plans.
• 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 Failure Mode and Effects Analysis), design review materials, and engineering reports to support program milestones and production readiness.
• Leadership and Mentorship: Mentor junior engineers on best practices and facilitate on-the-job learning
• Innovation and Continuous Improvement: Remain current with emerging technologies and trends of driveline and off-road vehicle systems. Drive innovation by proposing new solutions or improvements (such as novel torque management systems or lightweight materials) to keep the company’s truck and off-road platforms at the forefront of performance and reliability. Lead or contribute to advanced engineering projects aimed at improving driveline efficiency, durability, and functionality.
• 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 driveline 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 driveline 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
    • An ability to create complex part models, assemblies, and engineering drawings with proper GD&T annotation
  • Experience using engineering tools to create and modify 2D and 3D drawings
  • Familiarity with PDM (e.g., ENOVIA V6) or Windchill PLM systems
  • An ability to perform detailed component design and analytical calculations concerning strength, fatigue, and performance
  • 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.