Staff Design Release Engineer, Halfshafts and Spline Shafts

Rivian • Plymouth, MI

17d • Onsite

About The Position

Rivian is seeking a detail-oriented and driven Design Release Engineer (DRE) specializing in Halfshafts and Spline Shaft Design to join their Driveline Engineering team. This role involves owning the end-to-end lifecycle of halfshaft assemblies, constant velocity (CV) joints, and splined shaft components. Responsibilities include establishing the statement of requirements (SOR), concept development, packaging, detailed design, validation, manufacturing launch, and post-production support. The DRE will collaborate closely with cross-functional teams such as 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