Staff Design Release Engineer, Halfshafts and Spline Shafts

About the role

We are seeking a detail-oriented and driven Design Release Engineer (DRE) specializing in Halfshafts and Spline Shaft Design to join our Driveline Engineering team.

Responsibilities

• Design & CAD Release 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.
• Technical & System Integration 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.
• Create and maintain engineering documentation including DFMEAs, DVP&Rs, boundary diagrams, and design rules.
• Supplier & Manufacturing Collaboration 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.
• Validation & Quality Support 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.

Qualifications

• Education: Bachelor’s degree in Mechanical Engineering, Automotive Engineering, or a related technical discipline.
• Experience: 5+ years of professional engineering experience in automotive driveline, chassis, or powertrain systems (specifically focused on halfshafts, prop shafts, or power transmission shafts).
• Technical Knowledge: * 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).
• Communication: Excellent verbal and written communication skills to interface effectively with cross-functional teams and external suppliers.