Sr. Chassis Brake Systems Engineer

Hyundai American Technical Center Inc, (HATCI) is seeking a highly experienced Senior Chassis Engineer to lead the design, development, and validation of braking systems for U.S. pickup trucks and off-road vehicles. In this role you will be a key technical leader, overseeing the complete brake system development lifecycle - from concept and CAD modeling through testing and production release. You will ensure brake designs meet all performance targets, reliability and safety regulations and are optimized for SUV, truck and off-road use. This role demands creativity and problem-solving: you'll work closely with cross-functional teams (vehicle dynamics, powertrain, controls and manufacturing teams) to integrate advanced brake solutions. The ideal candidate has 8-10 years of hands-on Chassis - Brake System experience in an automotive OEM or Tier-1 environment, is highly proficient in CATIA V5, and demonstrates strong leadership and mentoring skills. 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.

* Lead Brake System Design & Development: Lead end-to-end design of brake systems and components (e.g. hydraulic boosters, calipers, rotors, pads, actuators) using CATIA V5. Develop robust mechanical layouts and CAD models that meet vehicle performance, packaging and manufacturability requirements.
* Simulation & Analysis: Perform and coordinate detailed engineering analysis (FEA, multi-body simulation, NVH studies, etc.) to predict brake performance, durability and noise-vibration-harshness (NVH) characteristics. 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. Coordinate with hardware and software groups (ABS/ESC controls, regenerative braking teams) to ensure seamless integration of brake functions.
* Supplier & Manufacturing Coordination: Partner with suppliers and internal manufacturing to select components (calipers, masters, valves, etc.) and processes. Ensure supplier designs meet our specifications and validate buildability and quality. Manage design reviews, DFMEA and cost targets in collaboration with procurement.
* Validation & 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 (performance curves, fade, pedal feel, braking distance) and drive design iterations to meet Federal and International requirements and internal standards.
* Technical Documentation: Create and maintain all project documentation. This includes 3D CAD models and 2D drawings (using CATIA V5), bills of materials (BOMs), specifications, test plans/reports and validation reports. Present technical findings and design reviews to management and cross-functional teams.
* Failure Analysis & 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 & Consumer reports to support warranty and quality issues.

* Leadership & 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: Occasional domestic and international travel (approximately 20%) to our Korean HQ, supplier facilities, chassis component manufacturers, and CA test tracks are expected. Travel may also include collaboration with off-site engineering teams or attendance at industry events.

• Education: Bachelor's or Master's degree in Mechanical Engineering, Automotive Engineering, or a related field.
• Experience: 8-10 years of relevant automotive engineering experience, with a significant portion in chassis or brake system design. Prior work at an OEM or Tier-1 supplier is required.
• Experience working on electric or hybrid vehicle brake systems (e.g. integration with regenerative braking or electromechanical brakes). Prior experience with pick-up trucks, SUVs or off-road vehicles and knowledge of their specific brake durability/fade requirements (e.g. severe environments, water fording) is a plus.
  Advanced Analysis: Proficiency in CAE tools (e.g. ANSYS, Nastran, MATLAB/Simulink) for advanced suspension modeling, dynamic simulations, or optimization is a plus.
  Vehicle Dynamics: 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.
  Additional CAD/CAE: Familiarity with CAD software (e.g. CATIA V6) and PDM (ENOVIA V6) or Windchill PLM systems.
• Certifications: Professional Engineer (PE) license or Six Sigma certification, if applicable, are advantageous.

* 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.

* A global environment that fosters diversity.

* Competitive salaries.

* Retirement savings and planning benefits.

* Flexible work hours, and hybrid work schedule options.

* Access to health savings accounts and flexible spending accounts.

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.

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  • HATCI is an Equal Opportunity Employer including Disabled and Veteran. VEVRAA Federal contractor.