Senior Design Engineer

About the Role:

As a Senior 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.

What You'll Do:

• Design and Engineering
• 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
• Own thrust unit configuration management, tracking various pedigrees and versions of hardware
• Lead detailed design and development of the thrust unit attach hardware from concept through production
• Assist in fairing integration design to optimize aerodynamic and thermal performance and system accessibility
• 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
• Analysis and Project Management
• Own and maintain comprehensive mass budget tracking for all thrust unit subsystems, identifying risks and weight optimization opportunities
• Perform structural and thermal analysis of thrust unit components using FEA tools
• 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
• Leadership and Collaboration
• Collaborate with vehicle integration, airframe, aerodynamics, loads, and systems teams to ensure integrated thrust unit meets all requirements
• 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

What You Need:

• Education & Experience
• Bachelor's Degree in mechanical/aerospace engineering, or related field
• Minimum of 4+ years of mechanical design experience, preferably in aerospace or automotive systems
• Proven experience with system-level integration, interface management, and mount design
• Experience with propulsion system integration or similar rotating machinery applications
• 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
• Strong understanding of structural analysis and FEA software packages (ANSYS, NASTRAN preferred)
• Knowledge of aerospace fastening methods, mounting systems, and structural interfaces
• Experience with mass budgeting, configuration management, and systems integration
• Understanding of manufacturing processes for aerospace structural components
• Communication and Organization
• 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
• Additional Requirements
• Availability for domestic travel as needed
• Demonstrated commitment to safety and quality in engineering practices

Bonus Qualifications:

• Aerospace development and certification experience
• Experience with electric propulsion systems or hybrid powertrains
• Background in aircraft structural design and certification requirements
• Self-motivated with exceptional attention to detail and systems-thinking approach
• Track record of successful product integration and launch experience
• Experience with vibration isolation and dynamic system mounting

Compensation:

At Archer, we reward exceptional performance that supports our business strategy. For this position, we are targeting a base salary range of $134,400 - $168,000, 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.