Automotive Packaging & Chassis Structural Engineer

Project Overview We are an EV/ automotive startup developing a premium, minimalist luxury SUV tailored for rough-terrain urban markets (similar to the Arrival and Lucid Gravity concepts). The vehicle utilizes a modified, stretched commercial vehicle rolling skateboard (retaining robust, locally serviceable OEM axles, steering, suspension, and brakes) but features a completely custom, spacious composite body shell. We require a senior automotive structural design expert to map our hardpoints, design a high-strength steel chassis extension/subframe, and integrate a heavy-duty swappable battery tray system. This is a milestone-based, contract-to-hire position. Core Technical Requirements & Payload ConstraintsChassis Modification: Design a structural extension and subframe to stretch a commercial utility steel ladder-frame/reinforced chassis. Payload Integration: Cleanly package and mount:2x Main Plug-and-Play Battery Packs (217 kg each)1x Power Distribution Unit (PDU) + Inverter system1x Auxiliary Power Unit (Internal Combustion Generator for range extension) Swappable Battery Mechanism: Design a highly secure, drawer-style side-access docking mechanism. The packs must slide out horizontally at waist height. The locking mechanism must completely isolate the high-voltage connectors from structural load and vibration. Dynamic Load Optimization: The structural subframe and battery mounts must survive cyclic road fatigue and a minimum 8G to 10G vertical dynamic shock impact (simulating hitting severe potholes at speed under full payload). Required Expert Profile: 7+ years of experience in Automotive Body-in-White (BIW), chassis development, or low-volume specialized vehicle engineering.Mastery of SolidWorks or CATIA for advanced sheet metal and structural surface design.Proven capability in Finite Element Analysis (FEA) using Ansys, HyperMesh, or Nastran to validate stress, strain, and vibration fatigue. Deep understanding of Design for Manufacturing (DFM) for CNC laser cutting, CNC press brake sheet metal bending, and structural welding tolerances. Excellent English communication skills and experience working with distributed, remote teams. Project Deliverables 3D Master Assembly & Spatial Packaging Layout: Fixed hardpoint coordinates matching the donor running gear. Detailed Manufacturing CAD: 3D models of sheet metal trays, structural brackets, automatic deployable steps, and swappable locking pins. FEA Simulation Report: Full structural validation documentation proving the assembly handles a 10G pothole shock test. Production Blueprint Pack: Flat-pattern DXF files with precise bend radii allowances, and STEP files ready for high-precision CNC rapid prototyping. How to ApplyPlease submit your portfolio highlighting any chassis design, electric vehicle packaging, or suspension/subframe modifications. Briefly explain your approach to engineering a locking mechanism for a 217 kg moving mass under heavy vibration conditions. Tentative Budget & Milestone Breakdown Estimated Budget (USD)Milestone 1: Hardpoint Mapping & Spatial LayoutImport physical coordinates from local team. Lock 3D block-model positions for the 2x 217kg packs, generator, and PDU within the stretched chassis envelope. 1.5 Weeks for $1,00 Milestone 2: Subframe & Swappable Drawer DesignDetailed sheet metal modeling of structural mounting brackets, side-access battery drawers, locking latches, and automated side-step clearance channels.2.5 Weeks- $1,800 Milestone 3: Rough-Terrain FEA Simulation Virtual stress, fatigue, and 10G impact testing. Deliver a technical engineering report with modifications made to high-stress areas (adding gussets, varying metal thickness).1.5 Weeks- $1,200 Milestone 4: Production Blueprints & DFM Pack Exporting final, manufacturing-ready 2D drawings, assembly instructions, bend allowances, and clean STEP/DXF files for China rapid-fabrication shops.1 Week- $500 TOTALS Complete Digital Mechanical Skateboard Platform~6.5 Weeks$4,500