Senior Engineer, Suspension Structures

Job description

About the employer At the employer, we are creating exceptional mobility experiences through innovation to drive the world forward. Built on the employer’s proprietary technology and software-defined vehicle architecture, our award-winning vehicles bring our “Compromise Nothing™” approach to the global automotive market. That means refusing to choose between performance and sustainability, design and engineering, ambition and integrity. In the employer Air and the employer Gravity, we have designed and built vehicles that have redefined their segments, combining exceptional range, performance, design, and expansive space in a single experience. We achieve this through deep vertical integration, with design, engineering, and production happening in-house across our global offices and manufacturing facilities. Our teams come from industries around the world, united by a shared commitment to excellence. By refusing to settle, you can help redefine what’s possible and shape the future of mobility. Position Overview The Senior Engineer, Suspension Structures provides technical leadership and hands-on engineering support for suspension structural systems throughout vehicle launch, production ramp-up, and series manufacturing. This role serves as the primary plant engineering focal point for knuckles, control arms, subframes, links, bushings, wheel carriers, and related structural chassis components. The engineer works closely with Design Engineering, CAE, Manufacturing Engineering, Quality, Supplier Quality, Purchasing, and Plant Operations to ensure vehicle quality, safety, durability, NVH performance, and manufacturing efficiency. The role is critical for rapid production issue resolution, vehicle launch support, and continuous improvement. Responsible for sustaining engineering after initial product launch. This includes design and release of new parts as required such as to improve quality or the assembly process. Working with core engineering to ensure parts meet all design and validation requirements. Key Responsibilities Production Support & Issue Resolution • Serve as the plant technical expert for front/rear knuckles, upper/lower control arms, suspension links, front/rear subframes, crossmembers, structural brackets and mounts, bushings, and compliant joints. • Investigate and resolve vehicle build, fit-up, dimensional, durability, corrosion, and quality concerns. • Lead root cause analysis for manufacturing, supplier, and field issues. • Implement containment actions and drive permanent corrective actions. • Support daily production meetings and manufacturing escalations; minimize downtime related to chassis structural component issues. Launch & Program Support • Support prototype, DV, PV, and production vehicle builds. • Coordinate engineering change releases and plant implementation plans. • Track launch issues and ensure timely closure. • Support vehicle build events and launch reviews. Dimensional & Manufacturing Engineering • Support dimensional variation analysis and build quality improvement activities. • Investigate stack-up, tolerance, and alignment issues. • Collaborate with manufacturing teams to improve assembly robustness. • Support implementation of poka-yoke and process improvements. • Reduce rework and scrap associated with chassis structures. Structural Performance, Supplier Quality & Continuous Improvement • Support validation sign-off activities and production readiness reviews. • Interface directly with suspension structure suppliers and lead technical reviews for quality, production, dimensional, and durability concerns. • Support supplier containment and corrective action implementation. • Participate in supplier audits and launch readiness reviews. • Drive continuous improvement initiatives with suppliers and internal cross-functional teams. • Develop predictive quality monitoring strategies using production and warranty data. Sustaining Engineering • Responsible for the design and development of automotive chassis components and assemblies to deliver the highest level of performance in NVH, Durability, and Manufacturability while optimizing cost. • Work closely with other stake owners and attribute owners across the company such as Core engineering. Vehicle Safety, Vehicle Dynamics, NVH, Durability, Manufacturing, Design Studio, etc. • Cross functionally works with Manufacturing, Design and Product Development as well as with Purchasing, Supplier Quality, and Suppliers on items such as tool buy-offs and secondary component changes.

Requirements

• Deep understanding of suspension systems, structural chassis components, and vehicle dynamics fundamentals
• Strong working knowledge of durability engineering, manufacturing processes, GD&T, and tolerance stack-up analysis
• Proficiency with structured root cause analysis and corrective action methods
• Working knowledge of DFMEA, PFMEA, and DVP&R processes
• Hands-on troubleshooting mindset with ability to support production floor issue resolution
• Cross-functional leadership and communication skills across Engineering, Manufacturing, Quality, Supplier Quality, Purchasing, and Plant Operations
• Ability to support suppliers and internal teams through launch readiness, containment, corrective action, and continuous improvement
• Excellent communication skills across Vehicle Engineering, Manufacturing, Quality, Controls, Supplier Quality, Service Engineering, and Plant Operations
• Six Sigma Black Belt, Green Belt, Shannin RedX or other equivalent problem-solving methodology
• Experience in full life cycle development from concept to prototype to full production
• Ability to create testing plan and conduct / coordinate physical tests to prove out design concepts and ensure performance targets are being achieved
• Proficient in reading and interpreting GD&T. Coordinate virtual engineering and physical validation testing activities for your designs
• Hands-on practical experience in prototype assembly and production assembly with the willingness to assemble your own parts
• Be able to derive clamp load and torque values for critical joints
• Bachelor's degree in Mechanical Engineering, Automotive Engineering, Manufacturing Engineering, or a related technical field
• 5+ years of experience in automotive engineering, suspension systems, structural engineering, manufacturing engineering, or vehicle integration
• Experience supporting vehicle launches and production operations
• Strong understanding of suspension systems, structural chassis components, vehicle dynamics fundamentals, durability engineering, manufacturing processes, GD&T, root cause analysis methodologies, DFMEA, PFMEA, and DVP&R
• Excellent communication and cross-functional leadership abilities
• Experience with 3D CAD systems such as CATIA or similar software
• Design release engineering experience including engineering

Skills