Mechanical Design Engineer - Thermal and Ducting

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.

Responsibilities

Design thermal and ducting integration solutions for powertrain components on prototype aircraft including generators and turboshaft engines; Turn theoretical thermal solutions into real hardware by collaborating with aerothermal analysts to optimize duct designs for performance, pressure drop, and thermal efficiency; Design inlet and exhaust ducting systems for turboshaft engines and thermal management systems on aircraft; Select and integrate thermal management components including pumps, lines, fittings, and sensors; Collaborate with structural analysts to ensure designs meet strength, stiffness, and fatigue requirements; Work closely with powertrain engineers and airframe team to ensure proper integration of all systems; Own the prototype development process (requirements, design, BOM, procurement, assembly, test, etc.); Complete handbook calculations to verify system performance and component margins; Interface with suppliers to select COTS solutions where appropriate; Develop verification testing strategies and see your designs through rigorous process intensive testing (DO-160G, etc.); Create and review technical drawings, plans, and specifications; Support requirements development and documentation

Requirements

5+ years of engineering experience; Bachelor's degree in Mechanical Engineering; Exposure to integrating thermal systems or air breathing turbomachinery; Proficient in CAD (Solidworks, NX, etc.); Ability to manage CAD and complex assemblies in Team Center; Familiarity with aerospace hardware and fastener standards; Proficient in FEA using professional tools (NASTRAN, ANSYS, Abaqus, etc.); Experience designing metallic parts including machined components, sheet metal, and weldments; Fluent in GD&T and creating manufacturing drawings; Hands-on experience in multiple technical fields especially those related to carbon composite, sheet metal ducting, and metallic structures

Nice to have

Bachelor’s degree in Aerospace, Mechanical, or Electrical Engineering (or equivalent); Knowledge of, and experience within, electric powertrain systems or aerospace systems; Thorough understanding of engineering product development including design phases, manufacturing processes and global supply chain management; Familiarization with Atlassian Jira and Confluence for task management and collaborative documentation; Experience supporting vehicle development from concept/prototype aircraft phase through certification and mass production