Staff Design Release Engineer, Halfshafts and Spline Shafts

Rivian • Plymouth, MI

79d • Onsite

About The Position

We are seeking a detail-oriented and driven Design Release Engineer (DRE) specializing in Halfshafts and Spline Shaft Design to join our Driveline Engineering team. In this role, you will own the end-to-end lifecycle of halfshaft assemblies, constant velocity (CV) joints, and splined shaft components—from statement of requirements (SOR) establishment, concept development, packaging, and detailed design through validation, manufacturing launch, and post-production support. You will collaborate closely with cross-functional teams, including NVH, Vehicle Integration, Vehicle Manufacturing, Quality, and Tier-1 suppliers, to deliver high-performance, durable, and cost-effective driveline solutions.

Requirements

• Bachelor’s degree in Mechanical Engineering, Automotive Engineering, or a related technical discipline.
• 5+ years of professional engineering experience in automotive driveline, chassis, or powertrain systems (specifically focused on halfshafts, prop shafts, or power transmission shafts).
• Experience in major automotive CAD software (e.g., CATIA V5/V6, NX, or Creo).
• Deep understanding of CV joint kinematics, spline standards (ANSI/ISO/DIN), structural mechanics, and fatigue analysis.
• Practical application of GD&T (ASME Y14.5) and tolerance stack-ups.
• Familiarity with automotive development processes (APQP, DFMEA, DVP&R, PPAP).
• Excellent verbal and written communication skills to interface effectively with cross-functional teams and external suppliers.

Nice To Haves

• Master’s degree in Mechanical or Automotive Engineering.
• 5+ years of direct DRE experience releasing halfshafts or driveline components for major OEMs or Tier-1 suppliers.
• Experience with High-Voltage Powertrains / Electric Vehicles (EVs) and high-torque driveline requirements.

Responsibilities

• Lead the design, packaging, and engineering release of halfshaft assemblies, CV joints, boots, tripods, and splined connections (inboard and outboard).
• Conduct 3D CAD modeling and 2D drafting (Preferred), GD&T application, and tolerance stack-up analyses to ensure proper fitment and articulation across all suspension travel and steering angles.
• Optimize spline geometries (e.g., involute splines, retention mechanisms, circlips) for torque capacity, fatigue life, fretting wear prevention, and ease of assembly.
• Collaborate with Vehicle Integration and Chassis teams to define plunge requirements, joint articulation limits, dynamic angles, and clearance envelopes. DRE will own Plunge Angle Diagrams (PADs) for each halfshaft application.
• Work with NVH and Powertrain teams to minimize driveline-induced vibrations (e.g., shuffle, boom, dynamic imbalance) and optimize stiffness and mass.
• Create and maintain engineering documentation including DFMEAs, DVP&Rs, boundary diagrams, and design rules.
• Serve as the primary technical point of contact for Tier-1 driveline suppliers, managing technical specs, design reviews, and engineering change requests (ECRs).
• Interface with manufacturing and assembly plants to align on installation process and adherence to ergonomic requirements, resolve build issues, define torque specs, and optimize line-fit processes.
• Define physical test plans (torsional fatigue, ultimate strength, CV joint durability, high/low-temperature boot endurance, corrosion) and analyze test results.
• Lead root-cause analysis (e.g., 8D, Fishbone) for prototype or field failures related to wear, noise, boot rupture, or spline damage.

Benefits

• Robust medical/Rx, dental and vision insurance packages for full-time employees, their spouse or domestic partner, and children up to age 26.
• Coverage is effective on the first day of employment.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior