Senior Mechanical Design Engineer, Motor

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 GD&T.
• 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 packages (ANSYS, NASTRAN) for structural and thermal analysis.
• Self-motivated with exceptional attention to detail and ability to manage multiple priorities simultaneously.