Senior Mechanical Design Engineer, Motor

Archer is an aerospace company based in San Jose, California building an all-electric vertical takeoff and landing aircraft with a mission to advance the benefits of sustainable air mobility. We are designing, manufacturing, and operating an all-electric aircraft that can carry four passengers while producing minimal noise. Our sights are set high and our problems are hard, and we believe that diversity in the workplace is what makes us smarter, drives better insights, and will ultimately lift us all to success. We are dedicated to cultivating an equitable and inclusive environment that embraces our differences, and supports and celebrates all of our team members. 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. What You'll Do: Core Component Design 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. Analysis and Validation 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. Cross Functional Collaboration 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. What You Need: Education Experience 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. Technical Expertise Proficiency in 3D CAD modeling (NX preferred) and creation of detailed 2D drawings with GDT. 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. Communication Leadership 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. Additional Requirements Availability for domestic travel as needed. Demonstrated commitment to safety and quality in engineering practices. Bonus Qualifications: Aerospace development and certification experience (FAA/EASA). Experience with high-speed rotor dynamics and balancing. Familiarity with FEA software pac ... (truncated, view full listing at source)