Failure Analysis Engineer - NDT

Reliability is at the core of Electric Adventure Vehicles. This position sits in Rivian's Tustin, CA Failure Analysis Lab and is dedicated to non-destructive evaluation across Rivian's full product line.

• Own the lab's computed tomography and optical metrology capability, producing the high-fidelity imaging and dimensional data that drives root cause determination.
• Support programs spanning new product development, production line escapes, warranty, and field failures.
• Work as an integral member of the FA team in Tustin, in close partnership with the FA engineers at our Normal, IL production facility.
• Serve cross-functional customers across Energy Storage, Chassis, Body, Thermal, Closures, and Electrical Engineering — from battery cells and power electronics to castings, closures, and structural assemblies.
• Operate in a hands-on, high-throughput environment where the quality and speed of your imaging and analysis directly determine how quickly Rivian identifies and corrects hardware failures.

We are looking for expert-level, hands-on depth in the following areas:

• Setup, operation, and technique development of the NSI X5000 CT scanner with 225 kV and 450 kV X-ray sources, or an equivalent industrial CT system — including source and detector selection, scan parameter optimization, and radiation safety practice.

• Expertise with VG Studio Max reconstruction software, or equivalent, covering volume reconstruction, porosity and void analysis, surface mesh generation, CAD-to-part nominal comparison, and dimensional measurement.

• Advanced capability in sample preparation techniques and in the operation of the scanning electron microscope with energy dispersive spectroscopy (SEM/EDS) for fractography, surface characterization, and elemental analysis.

• Advanced capability with the Keyence VR-6000 optical profilometer, or equivalent, and its associated diagnostic software for 3D surface and form measurement.

• Working knowledge and hands-on use of optical microscopy — Keyence VX-series, Zeiss, Olympus, or equivalent — and 2D X-ray inspection.

• Minimum of a Bachelor's degree in Materials Science, Mechanical Engineering, Physics, or a related engineering discipline.

• Minimum of five years of relevant hands-on experience.

• NDT Level 2 or Level 3 certification preferred.

• Automotive or other regulated-industry experience preferred.

• Ability to independently scope an analysis and determine the correct sequence of non-destructive examination prior to any destructive work.

• Comfort documenting findings in clear, well-visualized technical reports for both engineering and executive audiences.

• A self-directed approach, the ability to carry a high-volume analysis queue with minimal ramp, and a desire to help build a respectful, inclusive, and inspiring team culture.