Senior Engineer_ Chassis & Frame (EV Truck)

Job Description: Senior Engineer Chassis & Frame (EV Truck)

Location: Seetharampur Plant
Department: Mobility – Trucks
Reports To: Manager / Dy. Manager – Chassis / Vehicle Engineering

Key Responsibilities

• Chassis frame design and development for electric truck platforms from concept through production release.
• Define frame architecture, including long members, cross members, reinforcements, brackets, and mounting interfaces.
• Develop chassis layouts considering GVW/GCW, axle loads, wheelbase, overhangs, load distribution, packaging, and application requirements.
• Define frame section, material grade, thickness, reinforcement strategy, and cross-member configuration based on structural requirements.
• Ensure proper integration of chassis with cab, suspension, steering, axles, battery packs, traction motor/e-drive, air tanks, compressors, thermal systems, and other aggregates.
• Define and control mounting interfaces for battery cradles, powertrain, cab, suspension, fifth wheel/load body, towing devices, and auxiliary systems.
• Optimize chassis structures for strength, stiffness, durability, weight, and cost.
• Work closely with CAE teams for static strength, fatigue/durability, torsional stiffness, bending stiffness, modal, and load-case analysis.
• Define critical chassis load cases covering braking, acceleration, cornering, pothole, twist/diagonal wheel, gradient, curb impact, payload, towing, and application-specific operating conditions.
• Evaluate chassis behaviour under bending and torsional loads and ensure appropriate flexibility/stiffness at subsystem mounting locations.
• Manage chassis packaging and resolve clashes, hole conflicts, mounting conflicts, accessibility, and assembly issues through DMU/design reviews.
• Define frame drilling/hole strategy while maintaining required edge distance, hole spacing, structural integrity, and manufacturing feasibility.
• Perform GD&T, tolerance stack-up, interface control, fastener selection, joint design, and tightening requirements.
• Define requirements for bolted, riveted, and welded joints used in chassis structures.
• Support material selection including HSLA/high-strength steels, considering strength, fatigue, formability, weldability, availability, and cost.
• Define requirements for surface treatment, corrosion protection, painting/coating, and chassis durability.
• Ensure chassis designs meet DFM/DFA requirements, including forming, bending, punching/drilling, welding, coating, and assembly processes.
• Lead design reviews, DFMEA, DVP, risk assessments, technical sign-off, and engineering change management.
• Coordinate closely with Cab, Suspension, Steering, Brake, Battery, Powertrain, Electrical, Thermal, Vehicle Integration, CAE, Manufacturing, Quality, Sourcing, and Homologation teams.
• Support prototype vehicle builds, identify build issues, and drive corrective actions.
• Support chassis and vehicle-level DV/PV testing, including structural durability and proving-ground validation.
• Investigate chassis failures or field issues and perform root-cause analysis and design improvements.
• Ensure compliance with applicable CMVR, AIS, Automotive Industry Standards, and relevant national/international commercial-vehicle standards.
• Review supplier drawings, manufacturing feasibility, process capability, inspection requirements, and technical submissions.
• Prepare and maintain engineering documentation including 2D drawings, 3D models, BOMs, specifications, interface drawings, DVPs, DFMEAs, and technical sign-off documents.
• Support VA/VE, localization, weight reduction, and cost optimization activities without compromising structural performance or durability.

Technical Skills & Competencies

• Strong knowledge of commercial vehicle chassis and ladder-frame design.
• Strong understanding of frame bending, torsion, stiffness, fatigue, durability, and load paths.
• Good knowledge of long members, cross members, reinforcements, brackets, and structural joints.
• Proficiency in CAD tools such as CATIA / Creo.

Qualifications & Experience

• Bachelor’s / master’s degree in mechanical / Automobile / Automotive Engineering.
• 3–6years of experience in commercial vehicle chassis, frame, structural design, or vehicle integration.
• Hands-on experience in truck/bus chassis frame design and development preferred.
• Experience in electric truck/bus chassis development will be an advantage.
• Experience with medium/heavy commercial vehicles (M&HCV), tractor-trailers, tippers, or buses preferred.