Senior Powertrain Manufacturing Engineer Job at Archer Aviation (San Jose)

Job Description

As part of the mission at Archer, we’re scaling production of our cutting-edge Electric Propulsion System (EPS) — the heart of our eVTOL aircraft. EPS comprises the Electric Motor and Propeller assemblies and represents one of the most technically demanding, highly automated manufacturing systems in our factory. We’re looking for a Powertrain Manufacturing Engineer who is passionate about bridging design and production — someone who thrives on creating scalable manufacturing systems, optimizing complex processes, and building world-class hardware from the ground up.

Job Responsibility

Contribute to the design and scaling of Archer’s Electric Propulsion System production line — from concept to high-rate manufacturing — including layout, automation strategy, tooling, and ramp-up planning
Collaborate cross-functionally with Product Design, Quality, Facilities, and Manufacturing teams to bring new electric motor and propeller systems into production
Design for Manufacturability (DFM) efforts to ensure products are built efficiently, safely, and at scale
Develop and execute comprehensive manufacturing build plans — defining part flow, line layout, tools, equipment, and the manufacturing bill of materials (MBOM)
Specify and validate automation systems, tooling, and test equipment to support high-reliability production
Perform PFMEA (Process Failure Mode & Effects Analysis) to proactively identify and mitigate risk in the production system
Author and approve detailed work instructions for EPS assembly and installation
Support first article builds and production validation testing to ensure process stability and repeatability
Drive continuous improvement through Lean, Six Sigma, and structured problem-solving methodologies

Requirements

Bachelor’s degree in Electrical, Mechanical, or Manufacturing Engineering (or equivalent)
3+ years of relevant experience in manufacturing engineering — preferably in EV, aerospace, or advanced hardware production
Hands-on experience in equipment commissioning, OEE improvement, and maintenance program development (preventive/predictive)
Experience building mechanical and electronic assemblies using sophisticated manufacturing tools and equipment
Knowledge of CAD, PLM, MES, and ERP systems
Strong foundation in GD&T and statistical process control (SPC)
Demonstrated ability to use structured problem-solving tools such as DMAIC, 8D, or 5 Whys
Well-developed communication and documentation skills — able to translate complex technical challenges into clear actions
Self-starter attitude with the ability to thrive in a fast-paced, highly regulated environment

Nice to have

Experience with EV Drive Unit (DU) manufacturing — rotor, stator, or gearbox assembly
Background in industrial automation (PLC, robotics, gantries)
Familiarity with high-voltage systems, batteries, or electric motors
Knowledge of aircraft conformity or configuration management
Experience with NX and AutoCAD
Willingness to travel up to 10%

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Senior Powertrain Manufacturing Engineer

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