Senior Mechanical Design Engineer, Motor

As a Senior Mechanical Design Engineer on our Electric Propulsion Team, you'll be at the forefront of solving complex challenges that directly impact the performance, safety, and evolution of Archer's cutting-edge electric aviation technology. This role serves as the bridge between electromagnetic theory and physical reality, applying advanced mechanical engineering principles to turn analytical models into robust, high-performance electric motors.

What You'll Do:

• Core Component Design
• Lead the detailed mechanical design of stator assemblies, ensuring structural integrity and thermal performance requirements are met.
• Develop comprehensive insulation systems that meet durability requirements for high voltage aviation applications.
• Design lightweight, robust rotor assemblies, managing high centrifugal forces and dynamic loads.
• Create and review CAD models, technical drawings, and specifications.
• Analysis and Validation
• Collaborate with the CAE team to perform Finite Element Analysis (FEA) to verify strength and fatigue requirements are met.
• Participate in development testing to ensure thermal predictions and durability requirements are met.
• Lead or participate in triaging and resolving critical issues discovered during the design/development cycle.
• Cross Functional Collaboration
• Collaborate closely with the Electromagnetic team to translate their modeled designs into functioning, manufacturable parts.
• Partner with the Thermal team to support the development and validation of accurate thermal models.
• Coordinate with the Electric Propulsion design group to drive the mechanical integration of stator and rotor components into the main engine assembly.
• Partner with Manufacturing Engineering to implement DFM (Design for Manufacturing) feedback and ensure designs can be produced at scale.
• Work with Quality and Supply Chain teams to ensure components meet rigorous aviation standards.

What You Need:

• Education & Experience
• Bachelor’s or Master's Degree in Mechanical Engineering, Aerospace Engineering, or related field.
• Minimum of 7+ years of experience in the mechanical design of electric machines (motors/generators).
• Deep understanding of electric motor construction, including lamination stacks, winding techniques, magnet retention, and insulation materials.

• Technical Expertise
• Proficiency in 3D CAD modeling (NX preferred) and creation of detailed 2D drawings with GD&T.
• Strong knowledge of materials and manufacturing processes relevant to electric motors (e.g., VPI, potting, shrink fits, laser welding).
• Experience with thermal management and structural analysis of rotating machinery.
• Familiarity with the physics of electric motor operation, including performance determinants and losses. 

• Communication & Leadership
• Proven ability to organize and lead cross-functional technical initiatives.
• Excellent presentation and communication skills to influence decision-making.
• Capacity to translate complex technical concepts for diverse audiences.
• Additional Requirements
• Availability for domestic travel as needed.
• Demonstrated commitment to safety and quality in engineering practices.

Bonus Qualifications:

• Aerospace development and certification experience (FAA/EASA).
• Experience with high-speed rotor dynamics and balancing.
• Familiarity with FEA software packages (ANSYS, NASTRAN) for structural and thermal analysis.
• Self-motivated with exceptional attention to detail and ability to manage multiple priorities simultaneously.

At Archer, we aim to attract, retain, and motivate talent with the skills and leadership needed to grow our business. We drive a pay-for-performance culture and reward performance that support the Company's strategy. For this position, we are targeting a base pay range of $144,000 - $190,000. Actual compensation offered will be determined by 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.