Staff Design Engineer, Gearbox

About the Role:

As a Staff Design Engineer on our Electric Engine Gearbox 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 combines expertise in gear and bearing design with strategic problem-solving to ensure our electric propulsion systems meet the highest standards of reliability and performance.

What You'll Do:

• Design and Engineering
• Lead design and development of complex gearbox systems from concept through production
• Perform trade studies to optimize system mass, durability, and efficiency
• Support detailed designs of gears, shafts, bearings, and seals
• Develop lubrication requirements to support gear and bearing performance
• Create and review CAD models, technical drawings, and specifications
• Work with vendors to incorporate DFM feedback and ensure parts can be manufactured to specifications
• Analysis and Validation
• Perform gear and bearing analysis using ISO calculations and FEA 
• Help develop test plans and test fixtures to validate components
• Analyze test data and implement design improvements based on findings
• Serve as the primary technical expert for triaging and resolving critical issues during the design/development cycle
• Leadership and Collaboration
• Lead by example, actively designing alongside the team while providing technical oversight
• Mentor and/or oversee junior engineers
• Work with systems, safety, and reliability teams to inform DFMEA and ensure requirements are properly validated and understood
• Drive cross-functional project teams including manufacturing, quality, sourcing, and test engineering
• Participate in design reviews and provide technical expertise for critical decisions

What You Need:

• Education & Experience
• Bachelor’s Degree in mechanical/electrical engineering, physics, or related field
• Minimum of 8-12+ years of gearbox design experience
• Proven experience with gear specification, material selection, heat treatments, shaft layouts, bearing selection, spline rating, housing design, seal selection, and lubrication methods
• Experience with transmission and driveline testing procedures (aircraft or dynamometer)
• Experience generating Bills of Materials (BOM) and managing change control processes
• Technical Expertise
• Proficiency in CAD modeling (NX preferred), 2D drawings, tolerance analysis, and GD&T
• Familiarity with FEA software packages (ANSYS, NASTRAN, and Romax preferred) to analyze gear and bearing components
• Knowledge of manufacturing processes for gearbox components
• Communication and Organization 
• 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
• Self-motivated with exceptional attention to detail and ability to manage multiple priorities simultaneously
• Track record of innovation and continuous improvement in engineering systems
• Experience as technical team lead
  
  

At Archer, we reward exceptional performance that supports our business strategy. For this position, we are targeting a base salary range of $163,200-$204,000, with final compensation determined by your unique combination of job-related knowledge, skills, and experience.

Join our team and help revolutionize urban transportation through innovative electric aviation technology.

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.