Design Engineer, Motor

What you'll do:

• Engineer critical motor components including phase harnesses, wye connections, insulation systems, and high-voltage busbars with focus on creepage and clearance requirements for aviation applications
• Design plastic components for motors including terminal housings, insulation barriers, and cooling system components, optimizing for both electrical and mechanical properties
• Design and develop mechanical aspects of permanent magnet synchronous motors from concept through manufacturing implementation
• Apply electromagnetic principles, thermal management, and mechanical stress analysis to create robust motor configurations including stator slot geometry, rotor assemblies, and insulation systems.
• Implement design for manufacturing concepts to create motor designs that are cost effective, manufacturable, and high performance. Notable focus on insulated wire forming & stripping, laminated steel cores, plastic injection and overmolding, welded joints, and resin impregnation.
• Contribute to company standards for motor component CAD models and drawings, including detailed specifications for insulation systems and HV safety requirements.
• Collaborate with cross-functional teams including electromagnetics, thermal simulation, integrated test, quality, supply chain, safety, and manufacturing.
• Support manufacturing & test to validate and verify that motor designs meet performance, safety, and certification requirements

What you need:

• 5+ years of experience with electric motor design (aerospace, automotive, or other high-performance applications)
• Bachelor's degree in Mechanical Engineering, Electrical Engineering, or related field
• Demonstrated ability to design and analyze mechanical components and systems with a focus on electrical isolation, mechanical stress, thermal stress, chemical compatibility, and environmental durability.
• Understanding of motor mechanical design fundamentals including:
• Laminated steel core design and manufacturing processes
• High-voltage insulation systems and dielectric strength requirements
• Creepage and clearance calculations per IEC/UL standards
• Experience designing plastic components for electrical systems, with knowledge of:
• Engineering polymers suitable for motor applications (PPS, PEEK, PA)
• Plastic injection molding design principles (wall thickness, draft angles, gate locations)
• Machined plastic component design and tolerancing
• Material selection for dielectric strength, temperature resistance, and mechanical stability
• Knowledge of GD&T and experience creating part and assembly drawings for manufacturing
• Proficiency in CAD software (NX preferred, Solidworks, Catia or Creo) for electromechanical assemblies
• Experience with at least two of the following:
• Laminated electrical steel stator and rotor cores
• High-voltage phase harnesses and busbar systems
• Wire wound stator assemblies and insulation systems
• Overmolded electrical components and assemblies
• Welded copper joints, high current applications.
• Familiarity with motor manufacturing processes including core lamination, winding techniques, plastic molding, and assembly procedures
• Familiarity with PDM systems (Teamcenter preferred)
• Self-starter, team player, and desire to work in a fast-paced environment

Bonus Qualifications:

• Experience with (PMSM) permanent magnet synchronous motor design for aircraft or automotive applications
• Experience with motor testing and validation procedures
• Experience with plastic part design for manufacturing (DFM) and design for assembly (DFA)
• Knowledge of overmolding processes for electrical connectors and terminals
• Experience with thermoplastic and thermoset materials selection for motor applications
• Experience with thermal analysis and cooling system design for electric motors
• Knowledge of material selection for electromagnetic and structural applications in motors
• Basic understanding of aviation certification requirements for electrical systems

At Archer we aim to attract, retain, and motivate talent that possess the skills and leadership necessary to grow our business. We drive a pay-for-performance culture and reward performance that supports the Company’s business strategy. For this position we are targeting a base pay between $134,400.00 - $168,000.00. Actual compensation offered will be determined by factors such as job-related knowledge, skills, and experience.

Archer is committed to working with and providing reasonable accommodations to job applicants with physical or mental disabilities, and those with sincerely held religious beliefs. Applicants who may require reasonable accommodation for any part of the application or hiring process should provide their name and contact information to Archer’s People Team at [email protected]. Reasonable accommodations will be determined on a case-by-case basis.