Battery Manufacturing Engineer

Archer Aviation•San Jose, CA

50d•$125,430 - $166,800

About The Position

As part of the mission at Archer, we're designing, building, and scaling battery modules and packs from prototype to full-scale production. We're looking for a Senior or Staff Battery Manufacturing Engineer who is passionate about hands-on engineering, process excellence, and cutting-edge electric vehicle technology, this is your opportunity to make a tangible impact.

Requirements

Bachelor's or Master's degree in Engineering or a related field
3+ years of hands-on manufacturing experience, ideally in EV battery module/pack production.
Proven experience scaling from prototypes to high-volume production.
Track record in OEE improvement, preventative/predictive maintenance, and process optimization.
Strong knowledge of statistical process control, GD&T, and lean manufacturing principles.
Proficiency in data analysis tools (Minitab, JMP, Python, or equivalent).
Experience in root cause analysis (8D, 5-Why, Fishbone) and failure analysis.
Familiarity with safety standards (ANSI/RIA 15.06, OSHA).
Experience with CAD, PLM, MES, and ERP systems.
Understanding of PLCs, robotics, motion control, vision systems, and human-machine safety devices.
Ability to travel domestically and internationally.

Nice To Haves

Experience with thermoplastic part joining (e.g., ultrasonic welding).
Knowledge of aviation battery certification (DO-311A, DO-160, RTCA).
Experience with airworthiness, aviation-grade traceability, and configuration management.
Familiarity with FAR 23, Part 21, and FAA production certification requirements.

Responsibilities

Lead the design, development, and deployment of battery manufacturing lines at Archer facilities.
Define build sequences, process flows, cycle times, layouts, and manufacturability solutions.
Support PFMEA and other risk analysis activities to ensure robust, safe, and reliable manufacturing processes.
Develop equipment specifications and partner with suppliers through RFQ, PO, FAT/SAT, installation, and validation to achieve SOP readiness.
Prepare budgets, project schedules, and financial justifications for leadership review.
Create and execute Factory Acceptance Testing plans, overseeing testing through line development and launch.
Drive process control initiatives, focusing on quality, equipment capability, and overall efficiency.
Review and resolve quality notifications, participate in Material Review Boards, and implement corrective and preventive actions.
Maintain and optimize MES configurations, shop floor routings, process parameters, and data collection protocols.
Serve as a technical generalist on production lines, providing troubleshooting support during equipment downtime or process deviations.
Identify and lead continuous improvement programs, optimizing product flow, line efficiency, and ergonomics using 5S methodology.
Establish KPIs, track performance trends, and proactively mitigate operational risks.