Sr. Battery Safety and Abuse Engineer, Thermal

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.

As a Sr. Battery Safety and Abuse Engineer, Thermal, within Rivian's Battery Test and Validation team in Tustin, CA, you will be responsible for developing and executing advanced thermal safety and abuse testing for high-voltage battery systems. This role is critical to ensuring Rivian's innovative battery products meet the highest standards for safety, reliability, and regulatory compliance. You will work cross-functionally with design, validation, and other teams to develop, implement, and continuously improve test methods and protocols for electrical abuse scenarios.

You will also play a key role in root cause analysis, risk assessment, and the development of safety countermeasures for battery systems

• Lead the planning, execution, and analysis of thermal safety and abuse tests on battery modules, packs, and components
• Develop and refine test plans, procedures, and acceptance criteria in alignment with regulatory standards (e.g., UN38.3, FMVSS, IEC, UL) and Rivian's internal safety requirements
• Collaborate with design, validation, and safety engineering teams to define safety-critical requirements and ensure robust test coverage for new and existing battery architectures
• Support Failure Modes and Effects Analysis (FMEA), Design Verification Plan & Report (DVP&R), and root cause investigations for safety-related incidents or test failures
• Analyze test data, generate detailed technical reports, and present findings and recommendations to cross-functional stakeholders
• Drive continuous improvement in test methodologies, documentation, and data quality for electrical abuse and safety testing
• Mentor and train junior engineers and technicians in safe work practices, test execution, and data analysis
• Support the development and commissioning of new test facilities, equipment, and instrumentation for advanced abuse testing
• Participate in cross-functional development groups to drive new design innovations through testing and lessons learned
• Stay current with industry trends, regulatory changes, and emerging best practices in battery safety and abuse testing

• Bachelor's or Master's degree in Mechanical Engineering preferred;
  Electrical Engineering,or a related field acceptable with relevant experience
• 5+ years of relevant experience in battery safety, abuse testing, or high-voltage systems, preferably in the automotive or energy storage industry
• Strong first principles understanding of battery failure modes, underlying physics, and governing equations
• Hands‑on experience with battery test equipment (test cyclers, isolation meters, high‑speed DAQ, CAN tools, thermal chambers, etc.) and data analysis software
• Familiarity with FMEA, DVP&R, and root‑cause analysis methodologies
• Excellent written and verbal communication skills, with the ability to clearly document and present technical findings to diverse audiences
• Strong organizational skills, attention to detail, and learning agility
• Ability to work independently and collaboratively in a fast‑paced, dynamic environment.
• Willingness to work flexible hours and travel as needed (up to 30% domestic and international travel may be required)

• Experience with battery pack design, BMS, and integration in electric vehicles.
• Experience with thermal runaway propagation testing and mitigation strategies
• Familiarity with advanced data analysis, scripting, or automation tools (e.g., Python, MATLAB, Lab View, JMP).
• Certification or advanced training in electrical safety (e.g., NFPA 70E, OSHA, or equivalent).
• Prior experience working on heat transfer problems, combustion, gas flow analysis, energetic materials, or…