Design Engineer, Thermal and Lubrication

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 Design Engineer on our Thermal Lubrication System team, you'll play a critical role in developing advanced lubrication and thermal management systems that ensure optimal performance and reliability of Archer's electric propulsion technology. This position combines deep technical expertise in fluid systems design with hands-on development experience to create innovative solutions that push the boundaries of electric aviation performance. What You'll Do: System Design and Development Lead design and development of integrated thermal lubrication systems from initial concept through production implementation Design and specify pumps, filters, heat exchangers, pressure relief valves, and related system components Develop system architectures that optimize thermal management and lubrication performance Create detailed CAD models, technical drawings, and system specifications Collaborate with manufacturing teams to ensure designs are optimized for production Analysis and Modeling Perform 1D system modeling and simulation using tools such as GT-Power, AMESim, or MATLAB/Simulink Conduct thermal and fluid flow analysis to validate system performance Utilize CFD analysis (StarCCM+ preferred) to optimize component and system designs Develop and maintain system performance models for various operating conditions Support trade studies to balance system performance, weight, and packaging requirements Testing and Validation Design and develop custom lubrication test equipment and fixtures Plan and execute component and system-level testing programs Operate test equipment and analyze results to validate design performance Lead troubleshooting efforts and implement design improvements based on test findings Support certification testing requirements and documentation Technical Leadership and Collaboration Provide technical guidance and mentorship to junior engineers Interface with cross-functional groups including propulsion unit design, manufacturing, aerodynamics, and development test teams Support design reviews and provide expert technical recommendations Drive supplier relationships and technical discussions for key components Contribute to DFMEA processes and reliability assessments What You Need: Education Experience Bachelor's Degree in Mechanical Engineering, Aerospace Engineering, or related technical field Minimum of 5+ years of experience in fluid systems, lubrication systems, or thermal management design Proven track record of taking systems from concept through production Technical Expertise Proficiency in CAD modeling software (NX, Creo, or similar) and 2D drawings Strong experience with 1D modeling tools such as GT-Power, AMESim, or MATLAB/Simulink Understanding of fluid mechanics, heat transfer, and thermodynamics principles Knowledge of manufacturing processes for fluid system components Communication and Problem-Solving Strong analytical and problem-solving skills with attention to detail Excellent written and verbal communication skills Ability to work effectively in a fast-paced, collaborative environment Self-motivated with ability to manage multiple projects simultaneously Additional Requirements Willingness to travel as needed for testing and supplier visits Commitment to safety-first engineering practice ... (truncated, view full listing at source)