Sr CAE Engineer - Body

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. The team is seeking a motivated Senior CAE Engineer to perform CAE analysis for body structures and closures components at both the component and system levels. 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.

• Prepare and modify CAE models from CAD using HyperMesh, including creation of 1D, 2D shell, and 3D solid meshes for BIW and closures.
• Build complete CAE models from scratch, perform model check-runs, and ensure model quality and compliance with simulation standards.
• Conduct structural stiffness, strength, durability, static, dynamic, nonlinear, and fatigue analyses for body structures.
• Develop and execute analysis plans for subsystem-level assessments of BIW structures, closures, top hats, underbody systems, dash structures, front-end structures etc.
• Capture welds, joints, spot welds, hard-points, and boundary conditions according to established body structure and chassis simulation guidelines.
• Apply appropriate modeling techniques for stiffness, linear/nonlinear strength, fatigue, and welded-joint behavior, including incorporation of manufacturing effects.
• Guide physical test planning, develop test matrices, and correlate CAE predictions with test results using CPG, RLDA, and other relevant test inputs.
• Perform mechanical joint 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.
• Travel up to 5% domestic and international

Qualifications:

• 5+ years of experience in using CAE Body using Abaqus and Nastran.
• 5+ years of experience in using Pre & Post CAE modeling software, e.g., Ansa and HyperWorks.
• Technical report preparation experience.
• Ability to work independently with minimum guidelines.
• Strong oral and verbal communication skills.
• Master's degree in mechanical engineering or related discipline.

Preferred Experience:

• Hands-on experience on Chassis CAE analysis for automotive.