Staff Mechanical Design Engineer

Rivian•Carson, CA

3d•$137,800 - $172,200•Onsite

About The Position

As the staff mechanical engineer, you will execute the design of our next-generation Traction Inverter Modules from initial concept through mass production. You will be responsible for designing multiple critical components including busbars, metal housings, sealing interfaces, HV/LV harnesses, stampings and PCBAs, from the ground up. This role requires close collaboration with cross-functional teams and suppliers to resolve complex packaging and manufacturing challenges in a dynamic environment. This position is based at our Carson, CA facility and reports directly to the Mechanical Engineering Director.

Requirements

Bachelor’s degree in mechanical engineering or a related engineering discipline
6+ years of engineering experience specifically in the development and packaging of Power Electronics assemblies
Expert-level proficiency in CATIA V5 or V6 (3DEXPERIENCE), specifically within Part Design and Assembly Design workbenches
Proven track record designing for diverse processes, including high-pressure die casting, injection molding, and sheet metal fabrication
Deep experience in the design of high-voltage busbars, HV/LV wire harnesses and sealing/gasket systems
Practical knowledge of integrating components using laser welding, press-fit, soldering, heat staking and thermal interface materials (TIM)
High proficiency in GD&T (ASME Y14.5) and experience developing DFMEA documents and system-level validation plans (Mechanical, Electrical, and Thermal)
Working knowledge of the ENOVIA Product Lifecycle Management environment
Extensive experience managing external technical suppliers, ensuring quality and timeline adherence
Demonstrated ability to use structured root-cause analysis techniques to identify and resolve complex component failures
General knowledge of mechanical best practices for PCBA design and integration.
Prior experience in the Automotive industry (Tier 1 or OEM).
Thrives in a fast-paced environment.
Proficiency with Microsoft Project, Visio, and the standard Office suite.

Responsibilities

Lead the mechanical development of Traction Inverter Modules using CATIA V6/3DEXPERIENCE
Design and engineer a wide array of components, including high-pressure die castings, injection-molded plastics, busbars, sheet metal, high/low voltage harnesses, sealing interfaces, and PCBA mechanical integration
Manage the full release cycle of mechanical components using ENOVIA, ensuring data integrity and design maturity
Generate and maintain complex Top-Level Assembly Bills of Materials (BOM), ensuring all component attributes are captured with 100% accuracy
Drive weekly technical reviews with suppliers to close open design items, manage timelines, and ensure DFM (Design for Manufacturing) alignment
Act as the primary technical liaison for Supply Chain and Supplier Quality teams to resolve action items and maintain production schedules
Author critical engineering documents, including Component Technical Specifications (CTS), Statements of Work (SOW) for sourcing, and detailed assembly manuals
Lead the creation of DFMEAs and develop robust Design Verification (DV) test plans to ensure long-term product reliability
Provide on-site support for pre-production lines, including the design of specialized mechanical test fixtures and assembly aids
Collaborate closely with Manufacturing Engineering to design, validate, and commission the production line on schedule
Lead troubleshooting efforts for issues arising during prototype builds and scale-up
Spearhead the root cause investigation of field failures related to mechanical assemblies, implementing design improvements to prevent recurrence