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Archer Aviation Logo Archer Aviation · IT - Software Development

Senior Mechanical Design Engineer, Motor

United States, San Jose 144000.00 - 190000.00 USD / Year · Job Posted March 10, 2026
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Job Description

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.

Job Responsibility

  • 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
  • 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
  • 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

Requirements

  • 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
  • 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
  • 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
  • Availability for domestic travel as needed
  • Demonstrated commitment to safety and quality in engineering practices

Nice to have

  • 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
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