Staff Design Engineer - Gearbox, Advanced Projects

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 Staff Design Engineer on our Advanced Projects Gearbox 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 combines expertise in gear and bearing design with strategic problem-solving to ensure our electric propulsion systems meet the highest standards of reliability and performance.

What You'll Do:

• Design and Engineering

• Lead design and development of complex gearbox systems from concept through production

• Perform trade studies to optimize system mass, durability, and efficiency

• Support detailed designs of gears, shafts, bearings, and seals

• Develop lubrication requirements to support gear and bearing performance

• Create and review CAD models, technical drawings, and specifications

• Work with vendors to incorporate DFM feedback and ensure parts can be manufactured to specifications

• Analysis and Validation

• Perform gear and bearing analysis using ISO calculations and FEA

• Help develop test plans and test fixtures to validate components

• Analyze test data and implement design improvements based on findings

• Serve as the primary technical expert for triaging and resolving critical issues during the design/development cycle

• Leadership and Collaboration

• Lead by example, actively designing alongside the team while providing technical oversight

• Mentor and/or oversee junior engineers

• Work with systems, safety, and reliability teams to inform DFMEA and ensure requirements are properly validated and understood

• Drive cross-functional project teams including manufacturing, quality, sourcing, and test engineering

• Lead design reviews and provide technical expertise for critical decisions

What You Need:

• Education & Experience

• Bachelor’s Degree in mechanical engineering, physics, or related field

• Minimum of 8-12+ years of rotorcraft gearbox design experience

• Proven experience with gear specification, material selection, heat treatments, shaft layouts, bearing selection, spline rating, housing design, seal selection, and lubrication methods

• Experience with transmission and driveline testing procedures (aircraft or dynamometer)

• 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

• Familiarity with FEA software packages (ANSYS, NASTRAN, and Romax preferred) to analyze gear and bearing components

• Knowledge of manufacturing processes for gearbox components

• Communication and Organization

• 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

• Self-motivated with exceptional attention to detail and ability to manage multiple priorities simultaneously

• Track record of innovation and continuous improvement in engineering systems

• Experience as technical team lead

Compensation:

At Archer, we reward exceptional performance that supports our business strategy. For this position, we are targeting a base salary range of $163,200.00 - $204,000.00, 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.

Information collected and processed as part of any job applications you choose to submit is subject to Archer's Candidate Privacy Policy.

Archer is unable to provide work visa sponsorship for this position at the present time.

Archer is proud to be an Equal Opportunity employer committed to diversity and inclusivity in the workplace. All aspects of employment are decided on the basis of merit, qualifications, and business needs. We do not discriminate based upon race, color, religion, sex, sexual orientation, age, national origin, disability status, protected veteran status, gender identity or any other characteristic protected by federal, state or local laws.

Archer Aviation does not engage with external recruiting agencies/individual recruiters with whom it does not have a prior written agreement. Archer reserves the right to make use of any unsolicited resumes that it receives and bears no responsibility for payment of any fees asserted from the use of unsolicited resumes. If you are a recruiting agency or individual recruiter wishing to do business with Archer, please reach out to [email protected]. All employment processes are managed by the Archer People Team.