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Broomfield, Colorado, United States
Onsite
About the Role
As a Staff Chassis Systems Design Engineer, you will be responsible for the design, development, integration, and validation of vehicle chassis structures and related mechanical systems. This position will own components and assemblies from requirements definition and concept development through detailed design, prototype build, validation, and production release.
The ideal candidate has strong mechanical design fundamentals, CAD ability, understands structural load paths and vehicle-level interfaces, and can develop manufacturable designs using sound engineering judgment, analysis, and testing.
Design and develop vehicle chassis systems and components, including suspension, braking, drive unit integration, wheels and tires, structural members, brackets, mounts, crossmembers, and subframes from concept through production.
Support definition and translate vehicle- and system-level requirements into detailed designs that meet strength, stiffness, durability, mass, packaging, serviceability, cost, and manufacturability targets.
Define subsystem load cases and structural load paths, and perform engineering calculations including static loading, stress, deflection, bolted-joint analysis, fatigue, and appropriate factors of safety.
Develop component and assembly interfaces, mounting strategies, datum structures, tolerances, clearances, and packaging requirements; apply GD&T and tolerance analysis in accordance with ASME Y14.5.
Create, release, and maintain production-quality 3D CAD, engineering drawings, specifications, and other design documentation throughout the product development lifecycle.
Select appropriate materials and manufacturing processes based on design requirements, production volumes, cost, and performance, including welded/fabricated structures, sheet metal, machining, castings, forgings, and extrusions.
Lead or support engineering analysis and risk-assessment activities including design reviews, CAE, DFMEA, PFMEA, tolerance analysis, trade studies, and functional analysis.
Develop and execute component and subsystem Design Verification and Production Validation plans, evaluate test results and failures, and implement design improvements and corrective actions.
Support prototype and production vehicle builds, troubleshooting fit, function, packaging, manufacturing, and assembly issues through root-cause resolution.
Support supplier selection and serve as the primary engineering interface with chassis component suppliers throughout RFQ, DFM, prototyping, validation, tooling, and production readiness.
Collaborate with suspension, braking, powertrain, body, electrical, CAE, manufacturing, quality, and supplier engineering teams to ensure successful vehicle-level integration.
B.S. in Mechanical Engineering, Automotive Engineering, Aerospace Engineering, or a related technical discipline; M.S. preferred.
8+ years of relevant mechanical or structural design experience in automotive, commercial vehicle, off-highway, motorsports, aerospace, or a similar industry.
Demonstrated experience developing mechanical systems or components from concept through prototype, validation, and production release.
Understanding of mechanical engineering fundamentals, including vehicle loads, structural load paths, stress, stiffness, fatigue, bolted joints, and suspension and braking principles.
Proficiency with 3D CAD and engineering drawing creation; CATIA 3DEXPERIENCE experience preferred.
Working knowledge of GD&T, tolerance analysis, and design for manufacturing and assembly.
Experience with common chassis manufacturing processes, including welded steel or aluminum structures, sheet metal, machining, castings, forgings, or similar processes.
Experience working directly with suppliers, manufacturing teams, and cross-functional engineering organizations to resolve design and production issues.
Collaborative and detail-oriented, with strong written and verbal communication skills and a commitment to engineering quality and thoroughness.
5+ years of direct experience designing and integrating vehicle chassis, suspension, steering, braking, axle, wheel-end, frame, or subframe systems.
Experience developing vehicles or mechanical systems in low- to medium-volume production environments.
Experience with structural FEA, fatigue analysis, modal analysis, and vehicle durability analysis.
Experience developing and executing DVP&R or equivalent design verification and validation plans.
Experience applying AIAG/VDA DFMEA methodologies.
Hands-on experience with vehicle assembly, fabrication, machining, welding, instrumentation, or mechanical testing.
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