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Archer Aviation Logo Archer Aviation · IT - Software Development

Design Engineer - Thrust Unit Integration

United States, San Jose 172000.00 - 225000.00 USD / Year · Job Posted March 10, 2026
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Job Description

As a Design Engineer on our Thrust Unit team, you'll play a critical role in integrating and optimizing the complete propulsion system that powers Archer's revolutionary electric aircraft. This position combines systems-level thinking with detailed mechanical design expertise to ensure our thrust units—comprising electric engines, propellers, and tilting mechanisms—deliver exceptional performance while seamlessly integrating with our aircraft platforms.

Job Responsibility

  • Develop and maintain CAD and drawings to document interfaces between thrust unit subsystems and airframe interfaces
  • Own and maintain thrust unit envelope CAD models and keep out zones to enable comprehensive vehicle package studies
  • Maintain thrust unit configuration management, tracking various pedigrees and versions of hardware
  • Assist in defining assembly processes and techniques and standardizing across the department
  • Interface with maintenance team to ensure thrust unit designs meet serviceability goals and enable efficient maintenance operations
  • Collaborate with manufacturing team to ensure seamless aircraft integration processes, optimize assembly tooling design, and develop suitable shipping and handling solutions
  • Drive bolted joint analysis and validation
  • Maintain comprehensive mass budget tracking for all thrust unit subsystems, identifying risks and weight optimization opportunities
  • Conduct trade studies to optimize system integration, mass efficiency, and performance
  • Support test planning and validation activities for thrust unit assemblies
  • Analyze test data and implement design improvements based on findings
  • Work cross-functionally with sourcing and quality teams to support supplier selection, component qualification, and inspection requirements for integration components
  • Participate in design reviews and provide technical expertise for critical integration decisions
  • Drive improvements to existing processes and develop new procedures as needed

Requirements

  • Bachelor's Degree in mechanical/aerospace engineering, or related field
  • Experience with system-level integration and interface management
  • Experience generating Bills of Materials (BOM) and managing change control processes
  • Proficiency in CAD modeling (NX preferred), 2D drawings, tolerance analysis, and GD&T
  • Understanding of mass budgeting, configuration management, and systems integration
  • Knowledge of manufacturing processes for aerospace structural components including machining, joining methods, and composite manufacturing
  • Proven ability to coordinate cross-functional technical initiatives across multiple subsystem teams
  • Excellent documentation and communication skills for maintaining complex interface requirements
  • Capacity to manage multiple integration challenges and priorities simultaneously
  • Strong analytical and problem-solving skills for resolving interface conflicts
  • Availability for domestic travel as needed
  • Demonstrated commitment to safety and quality in engineering practices

Nice to have

  • Aerospace development and certification experience
  • Experience with electric propulsion systems or hybrid powertrains
  • Self-motivated with exceptional attention to detail and systems-thinking approach
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