Sr. Mechanical Engineer, Gearbox

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. Responsibilities • Design, develop, and validate gearboxes and actuators • Design, develop, and validate plastic gears and gear trains for angle sensors and other mechatronic sensing/actuation applications • Perform gearbox design calculations, tolerance analysis, and tooth form optimization using KISSsoft • Specify and verify gear quality and tolerance requirements in accordance with Standard: ISO 1328 • Apply plastic gear design guidelines per Standard: VDI 2736 accounting for shrinkage, thermal expansion, moisture absorption, and wear • Create detailed 3D models of plastic gears, gearboxes, shafts, etc. • Collaborate with electrical engineers to integrate gear trains with angle sensors and other position-sensing components • Coordinate injection-molded gear tooling, sampling, and validation efforts with Tier 1 and Tier 2 suppliers • Develop and execute design verification plans and reports (DVP&R) for gear performance, durability, and NVH • Lead and maintain design failure mode and effects analyses (DFMEAs) for gear and sensor assemblies • Prototype and iterate designs using hands-on fabrication, gear metrology, and lab testing to validate functionality Qualifications • Proven experience designing plastic (injection-molded) gears, including tooth form compensation, backlash management, and material selection • Proficiency in KISSsoft for gear design, calculation, and simulation • Working knowledge of Standard: ISO 1328 gear tolerance classifications • Familiarity with Standard: VDI 2736 plastic gear design and testing guidelines • Experience designing gears for angle sensors or similar rotary position sensor gear trains • Proficient in 3D/2D CAD (Catia V5/V6 preferred) and Multibody dynamics (MBD) • Strong knowledge of GD&T and tolerance stack-up analysis • Solid foundation in polymer material properties, injection molding processes, and gear metrology • Familiarity with PLM systems, BOM structuring, engineering changes, and deviation processes Pay Disclosure Salary Range Irvine-Based Applicants: $107,800-$134,800 (actual compensation will be determined based on experience, and other factors permitted by law). Benefits Summary: Rivian provides 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. Equal Opportunity Rivian is an equal opportunity employer and complies with all applicable federal, state, and local fair employment practices laws. All qualified applicants will receive consideration for employment without regard to race, color, religion, national origin, ancestry, sex, sexual orientation, gender, gender expression, gender identity, genetic information or characteristics, physical or mental disability, marital/domestic partner status, age, military/veteran status, medical condition, or any other characteristic protected by law. Rivian is committed to ensuring that our hiring process is accessible for persons with disabilities. 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How We Use AI in Our Hiring Process: To ensure transparency, we want candidates to know that Rivian uses iCIMS Talent Cloud Artificial Intelligence (TCAI) and AI-enabled tools to assist with screening, reviewing, organizing and highlighting profiles and applications that match the key requirements for each role. AI does not make hiring decisions: Qualified candidate applications are reviewed by a member of our team, and all decisions throughout the process are made by humans. We use AI to support efficiency and consistency, not to replace human judgment. We are committed to a fair, thoughtful, and equitable experience for every candidate. Participation in AI profile matching is entirely voluntary. If you prefer that your profile not be used in this process, you can opt out at any time. Opting out means your profile will be excluded from automated matching and will not be surfaced for additional roles through this system. 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