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Staff Design Engineer - Gearbox, Advanced Products

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Archer Aviation

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Location:
United States , San Jose

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Category:
IT - Software Development

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Contract Type:
Not provided

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Salary:

163200.00 - 204000.00 USD / Year
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Job Description:

As a Staff Design Engineer on our Advanced Projects 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.

Job Responsibility:

  • 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
  • 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
  • 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
  • Lead design reviews and provide technical expertise for critical decisions

Requirements:

  • Bachelor’s Degree in mechanical engineering, physics, or related field
  • Minimum of 8-12+ years of rotorcraft 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
  • 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
  • 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
  • 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

Additional Information:

Job Posted:
December 06, 2025

Employment Type:
Fulltime
Work Type:
On-site work
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