Sr. FRT & RR Suspension Engineer

About the Role

The Sr. Front & Rear Suspension Engineer will lead design, development, and validation efforts for front and rear suspension systems in U.S. SUV, pickup truck, and off-road vehicles. This role involves creating robust, high-performance suspension architectures and collaborating with cross-functional teams to ensure seamless integration, durability, and reliability.

Responsibilities

• Lead end-to-end design of front and rear suspension components (e.g., control arms, springs, dampers, linkages, subframes, bushings) using CATIA V5, including 3D models, 2D drawings, and CAD release for prototyping and production.
• Coordinate FEA and kinematic/dynamic analyses with CAE teams to ensure designs meet strength, stiffness, durability, and ride/handling targets; analyze static, dynamic, and fatigue loads to optimize weight, cost, and performance.
• Develop and document suspension concepts and packaging layouts, considering vehicle geometry, articulation, ground clearance, steering geometry, and off-road requirements.
• Define, support, and execute validation plans for suspension systems, including test plan creation, prototype builds, bench testing, and full-vehicle tests (e.g., durability, NVH, ride comfort, handling, off-road performance).
• Analyze test data correlation with simulation results and drive design refinements as needed.
• Collaborate with suppliers on design and development, providing technical direction, reviewing CAD models/drawings, and managing the supplier design review process to ensure deliverables meet specifications and quality standards.
• Lead and participate in design reviews, DFMEA/PFMEA sessions, and design-for-manufacturing discussions; prepare and maintain engineering documents (e.g., specifications, test reports, control plans) in compliance with industry and regulatory standards.
• Create and maintain detailed engineering documentation, including 3D models, 2D drawings (with GD&T), technical specifications, DFMEAs, design review materials, and engineering reports to support program milestones.
• Investigate and resolve engineering issues during development and post-launch; implement corrective actions and drive continuous improvement of suspension designs and processes.
• Review IQS, VDS, J.D. Power, and Consumer Reports to address warranty and quality issues.
• Work closely with manufacturing, quality, and product engineering teams to ensure production feasibility and serviceability; support APQP/PPAP processes for vehicle program launches.
• Mentor junior engineers on best practices and facilitate on-the-job learning.
• Travel up to 20% domestically and internationally.

Requirements

• 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 for pickup trucks, SUVs, or off-road vehicles (experience with electric/hybrid vehicle suspension systems is highly preferred).
• In-depth understanding of vehicle ride and handling, off-road performance, NVH considerations, and suspension systems (solid axle and independent) in heavy-duty trucks/SUVs.
• Proficiency in CATIA V5; familiarity with other CAD software (e.g., CATIA V6, NX, SolidWorks) and PDM/PLM systems (e.g., ENOVIA V6, Windchill) is beneficial.
• Hands-on experience with mechanical analysis (FEA, analytical calculations) and suspension kinematics.
• Experience planning and executing vehicle/component tests (e.g., durability rigs, track testing, NVH evaluations).
• Knowledge of manufacturing engineering design, tooling processes, and materials.
• Strong problem-solving skills to diagnose complex issues (e.g., failure analysis) and develop solutions under tight timelines.
• Excellent written, oral, interpersonal, and leadership skills; ability to explain technical topics to diverse stakeholders.
• Proficiency in Microsoft Office (Excel, Outlook, PowerPoint, Word) for report/spreadsheet preparation.
• Flexibility to adapt to program/process changes and strong time management/organizational skills.
• Valid Driver’s License and satisfactory driving record.

Preferred Qualifications

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

Benefits

• Zero-dollar employee premiums on medical, dental, and vision coverage for you and your family.
• 100% employer-paid disability and life insurance.
• Generous paid time off, including vacation, sick leave, and holidays.
• Competitive salaries.
• Retirement savings and planning benefits (e.g., 401k).
• Access to Health Savings Accounts (HSA) and Flexible Spending Accounts (FSA).
• Flexible work hours.
• Global work environment fostering diversity.