Sr. Manufacturing Design Engineer - eMotor

Archer • San Jose, CA

5h • $126,700 - $158,400 • Onsite

About The Position

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. We are seeking a deeply technical, hands-on Sr. Manufacturing Design Engineer to serve as the primary bridge between R&D product design and physical production execution. In this role, you will lead complex electric propulsion hardware (stators, rotors, housings, gearboxes) through its full evolution—from early-stage prototyping to repeatable, scalable mass production. You will thrive in high-ownership environments, applying structured engineering principles to solve complex manufacturing challenges under tight schedules. Your primary focus will be establishing, validating, and optimizing production systems for the EPS across multiple aircraft programs.

Requirements

• Bachelor’s degree in Mechanical, Manufacturing, or Electrical Engineering with 3–6+ years of hands-on experience (EV, Automotive, or Aerospace preferred).
• Direct experience building and troubleshooting mechanical and electronic assemblies using advanced automated manufacturing equipment.
• Proven expertise in Statistical Process Control (SPC), Geometric Dimensioning and Tolerancing (GD&T), and drawing reviews.
• Demonstrated track record of scaling production lines from early prototype builds through high-volume mass production.
• Proficiency using formal methodologies (Lean, Six Sigma, DMAIC, 8D, 5-Why) to resolve high-level equipment and process performance issues.
• Daily working proficiency with CAD (e.g., NX, AutoCAD), PLM, MES, and ERP systems.
• Exceptional written and verbal communication skills with the resilience to thrive in a fast-paced, highly regulated, and dynamic environment.

Nice To Haves

• Direct hands-on manufacturing experience with EV Drive Units (DU), specifically rotor, stator, or gearbox assembly processes.
• Hands-on experience programming and troubleshooting industrial robotics, gantries, and PLCs.
• Knowledge of high-voltage (HV) wiring, battery modules, and electric motor safety standards.
• Familiarity with eVTOL systems, aircraft configuration management, and airworthiness conformity processes.
• Experience establishing Preventive/Predictive Maintenance programs and driving Overall Equipment Effectiveness (OEE) improvements.
• Willingness to travel up to 10% for vendor oversight and equipment integration.

Responsibilities

• Spearhead DFM/DFA initiatives, collaborating with cross-functional teams (Product Design, Quality, Facilities) to optimize electric powertrain system (EPS) manufacturability.
• Lead initial prototype build plans, execute process trials, develop custom tooling, and drive system builds through equipment qualification and production ramp-up.
• Define technical specifications for automation equipment, tools, and custom fixtures, managing vendor development through final Acceptance Testing (FAT/SAT).
• Develop comprehensive build plans, including plant line layouts, optimized part flow, manufacturing methods, and accurate Manufacturing Bills of Materials (MBOM).
• Conduct PFMEAs, establish validation/calibration protocols, and author standardized work instructions to ensure zero-defect assembly.
• Monitor pilot line performance, drive Root Cause Corrective Actions (RCCA), and optimize cycle times for mass production readiness.

Benefits

• Base pay between $126,700 - $158,400
• Commitment to working with and providing reasonable accommodations to job applicants with physical or mental disabilities, and those with sincerely held religious beliefs.
• Commitment to provide a safe workplace and a safe aircraft.
• Equal Opportunity employer committed to diversity and inclusivity in the workplace.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior