Staff Design Engineer - Gearbox, Advanced Projects

Archer•San Jose, CA

1d•$163,200 - $204,000

About The Position

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.

Requirements

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
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
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
Availability for domestic travel as needed
Demonstrated commitment to safety and quality in engineering practices

Nice To Haves

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

Responsibilities

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
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
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