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Sr. Power Electronics Mechanical Engineer
About Rivian Rivian is on a mission to keep the world adventurous forever. This goes for the emissions-free Electric Adventure Vehicles we build, and the curious, courageous souls we seek to attract.
As a company, we constantly challenge what’s possible, never simply accepting what has always been done. We reframe old problems, seek new solutions and operate comfortably in areas that are unknown. Our backgrounds are diverse, but our team shares a love of the outdoors and a desire to protect it for future generations.
Role Summary As a Sr Mechanical Engineer, you will be working on our next-generation Power Electronics Modules from initial concept through to full-scale production. You will be responsible for designing critical components including Busbars, metal housings, sealing interfaces, and HV/LV harnesses, Plastic Injection molded parts from the ground up. This role requires close collaboration with cross-functional teams to resolve complex packaging challenges.
This position is based at our Carson, CA facility and reports directly to the Sr. Mechanical Engineering Manager.
Responsibilities
- Lead the mechanical development of Power Electronics 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
- Collaborate with Systems team on DFMEAs and develop robust Design Verification (DV) test plans to ensure long-term product reliabilit
- 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
- Bachelor’s degree in mechanical engineering or a related engineering discipline
- 4+ 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 startup environment
- Proficiency with Microsoft Project, Visio, and the standard Office suite
