Senior Design Engineer, Thrust Unit Integration

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.

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 5-8+ 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 Qu