Design Engineer - Thrust Unit Integration

As a Design Engineer on our Thrust Unit team, you'll play a critical role in integrating and optimizing the complete propulsion system that powers Archer's revolutionary electric aircraft. This position combines systems-level thinking with detailed mechanical design expertise to ensure our thrust units—comprising electric engines, propellers, and tilting mechanisms—deliver exceptional performance while seamlessly integrating with our aircraft platforms.

What You'll Do:

• Design and Engineering
• Develop and maintain CAD and drawings to document interfaces between thrust unit subsystems and airframe interfaces
• Own and maintain thrust unit envelope CAD models and keep out zones to enable comprehensive vehicle package studies
• Maintain thrust unit configuration management, tracking various pedigrees and versions of hardware
• Assist in defining assembly processes and techniques and standardizing across the department
• Interface with maintenance team to ensure thrust unit designs meet serviceability goals and enable efficient maintenance operations
• Collaborate with manufacturing team to ensure seamless aircraft integration processes, optimize assembly tooling design, and develop suitable shipping and handling solutions
• Analysis and Project Management
• Drive bolted joint analysis and validation
• Maintain comprehensive mass budget tracking for all thrust unit subsystems, identifying risks and weight optimization opportunities
• Conduct trade studies to optimize system integration, mass efficiency, and performance
• Support test planning and validation activities for thrust unit assemblies
• Analyze test data and implement design improvements based on findings
• Collaboration
• Work cross-functionally with sourcing and quality teams to support supplier selection, component qualification, and inspection requirements for integration components
• Participate in design reviews and provide technical expertise for critical integration decisions
• Drive improvements to existing processes and develop new procedures as needed

What You Need:

• Education & Experience
• Bachelor's Degree in mechanical/aerospace engineering, or related field
• Experience with system-level integration and interface management
• 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
• Understanding of mass budgeting, configuration management, and systems integration
• Knowledge of manufacturing processes for aerospace structural components including machining, joining methods, and composite manufacturing
• Communication and Organization
• Proven ability to coordinate cross-functional technical initiatives across multiple subsystem teams
• Excellent documentation and communication skills for maintaining complex interface requirements
• Capacity to manage multiple integration challenges and priorities simultaneously
• Strong analytical and problem-solving skills for resolving interface conflicts
• Additional Requirements
• Availability for domestic travel as needed
• Demonstrated commitment to safety and quality in engineering practices

Bonus Qualifications:

• Aerospace development and certification experience
• Experience with electric propulsion systems or hybrid powertrains
• Self-motivated with exceptional attention to detail and systems-thinking approach

At Archer, we aim to attract, retain, and motivate talent with the skills and leadership needed to grow our business. We drive a pay-for-performance culture and reward performance that support the Company's strategy. For this position, we are targeting a base pay range of $172,000 - $225,000. Actual compensation offered will be determined by job-related knowledge, skills, and experience.

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 people@archer.com. Reasonable accommodations will be determined on a case-by-case basis.