Archer
Senior Mechanical Design Engineer: Electric Motor
Archer, San Jose, California, United States, 95199
Senior Mechanical Design Engineer: Electric Motor
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 committed to cultivating an equitable and inclusive environment that embraces our differences. Base pay range $134,400.00/yr - $168,000.00/yr Salary information retrieved from the job description. For this position we are targeting a base pay between $134,400.00 - $168,000.00. Actual compensation offered will be determined by factors such as job-related knowledge, skills, and experience.
What you’ll do
Engineer critical motor components including phase harnesses, wye connections, insulation systems, and high-voltage busbars with focus on creepage and clearance requirements for aviation applications
Design plastic components for motors including terminal housings, insulation barriers, and cooling system components, optimizing for both electrical and mechanical properties
Design and develop mechanical aspects of permanent magnet synchronous motors from concept through manufacturing implementation
Apply electromagnetic principles, thermal management, and mechanical stress analysis to create robust motor configurations including stator slot geometry, rotor assemblies, and insulation systems
Implement design for manufacturing concepts to create motor designs that are cost effective, manufacturable, and high performance, with focus on insulated wire forming & stripping, laminated steel cores, plastic injection and overmolding, welded joints, and resin impregnation
Contribute to company standards for motor component CAD models and drawings, including detailed specifications for insulation systems and HV safety requirements
Collaborate with cross-functional teams including electromagnetics, thermal simulation, integrated test, quality, supply chain, safety, and manufacturing
Support manufacturing & test to validate and verify that motor designs meet performance, safety, and certification requirements
What you need
5+ years of experience with electric motor design (aerospace, automotive, or other high-performance applications)
Bachelor’s degree in Mechanical Engineering, Electrical Engineering, or related field
Demonstrated ability to design and analyze mechanical components and systems with a focus on electrical isolation, mechanical stress, thermal stress, chemical compatibility, and environmental durability
Understanding of motor mechanical design fundamentals including
Laminated steel core design and manufacturing processes
High-voltage insulation systems and dielectric strength requirements
Creepage and clearance calculations per IEC/UL standards
Experience designing plastic components for electrical systems, with knowledge of
Engineering polymers suitable for motor applications (PPS, PEEK, PA)
Plastic injection molding design principles (wall thickness, draft angles, gate locations)
Machined plastic component design and tolerancing
Material selection for dielectric strength, temperature resistance, and mechanical stability
Knowledge of GD&T and experience creating part and assembly drawings for manufacturing
Proficiency in CAD software (NX preferred, SolidWorks, Catia or Creo) for electromechanical assemblies
Experience with at least two of the following
Laminated electrical steel stator and rotor cores
High-voltage phase harnesses and busbar systems
Wire wound stator assemblies and insulation systems
Overmolded electrical components and assemblies
Welded copper joints, high current applications
Familiarity with motor manufacturing processes including core lamination, winding techniques, plastic molding, and assembly procedures
Familiarity with PDM systems (Teamcenter preferred)
Self-starter, team player, and desire to work in a fast-paced environment
Bonus Qualifications
Experience with (PMSM) permanent magnet synchronous motor design for aircraft or automotive applications
Experience with motor testing and validation procedures
Experience with plastic part design for manufacturing (DFM) and design for assembly (DFA)
Knowledge of overmolding processes for electrical connectors and terminals
Experience with thermoplastic and thermoset materials selection for motor applications
Experience with thermal analysis and cooling system design for electric motors
Knowledge of material selection for electromagnetic and structural applications in motors
Basic understanding of aviation certification requirements for electrical systems
Archer is committed to equal opportunity and inclusivity. We do not discriminate based on race, color, religion, sex, sexual orientation, age, national origin, disability status, protected veteran status, gender identity or any other characteristic protected by law. Reasonable accommodations will be provided to applicants upon request.
Archer does not engage with external recruiting agencies without a prior written agreement. If you are a recruiting agency or individual recruiter, please contact People@archer.com. All employment processes are managed by the Archer People Team.
Seniority level
Mid-Senior level Employment type
Full-time Job function
Engineering and Information Technology Industries Airlines and Aviation Referrals increase your chances of interviewing at Archer by 2x
#J-18808-Ljbffr
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 committed to cultivating an equitable and inclusive environment that embraces our differences. Base pay range $134,400.00/yr - $168,000.00/yr Salary information retrieved from the job description. For this position we are targeting a base pay between $134,400.00 - $168,000.00. Actual compensation offered will be determined by factors such as job-related knowledge, skills, and experience.
What you’ll do
Engineer critical motor components including phase harnesses, wye connections, insulation systems, and high-voltage busbars with focus on creepage and clearance requirements for aviation applications
Design plastic components for motors including terminal housings, insulation barriers, and cooling system components, optimizing for both electrical and mechanical properties
Design and develop mechanical aspects of permanent magnet synchronous motors from concept through manufacturing implementation
Apply electromagnetic principles, thermal management, and mechanical stress analysis to create robust motor configurations including stator slot geometry, rotor assemblies, and insulation systems
Implement design for manufacturing concepts to create motor designs that are cost effective, manufacturable, and high performance, with focus on insulated wire forming & stripping, laminated steel cores, plastic injection and overmolding, welded joints, and resin impregnation
Contribute to company standards for motor component CAD models and drawings, including detailed specifications for insulation systems and HV safety requirements
Collaborate with cross-functional teams including electromagnetics, thermal simulation, integrated test, quality, supply chain, safety, and manufacturing
Support manufacturing & test to validate and verify that motor designs meet performance, safety, and certification requirements
What you need
5+ years of experience with electric motor design (aerospace, automotive, or other high-performance applications)
Bachelor’s degree in Mechanical Engineering, Electrical Engineering, or related field
Demonstrated ability to design and analyze mechanical components and systems with a focus on electrical isolation, mechanical stress, thermal stress, chemical compatibility, and environmental durability
Understanding of motor mechanical design fundamentals including
Laminated steel core design and manufacturing processes
High-voltage insulation systems and dielectric strength requirements
Creepage and clearance calculations per IEC/UL standards
Experience designing plastic components for electrical systems, with knowledge of
Engineering polymers suitable for motor applications (PPS, PEEK, PA)
Plastic injection molding design principles (wall thickness, draft angles, gate locations)
Machined plastic component design and tolerancing
Material selection for dielectric strength, temperature resistance, and mechanical stability
Knowledge of GD&T and experience creating part and assembly drawings for manufacturing
Proficiency in CAD software (NX preferred, SolidWorks, Catia or Creo) for electromechanical assemblies
Experience with at least two of the following
Laminated electrical steel stator and rotor cores
High-voltage phase harnesses and busbar systems
Wire wound stator assemblies and insulation systems
Overmolded electrical components and assemblies
Welded copper joints, high current applications
Familiarity with motor manufacturing processes including core lamination, winding techniques, plastic molding, and assembly procedures
Familiarity with PDM systems (Teamcenter preferred)
Self-starter, team player, and desire to work in a fast-paced environment
Bonus Qualifications
Experience with (PMSM) permanent magnet synchronous motor design for aircraft or automotive applications
Experience with motor testing and validation procedures
Experience with plastic part design for manufacturing (DFM) and design for assembly (DFA)
Knowledge of overmolding processes for electrical connectors and terminals
Experience with thermoplastic and thermoset materials selection for motor applications
Experience with thermal analysis and cooling system design for electric motors
Knowledge of material selection for electromagnetic and structural applications in motors
Basic understanding of aviation certification requirements for electrical systems
Archer is committed to equal opportunity and inclusivity. We do not discriminate based on race, color, religion, sex, sexual orientation, age, national origin, disability status, protected veteran status, gender identity or any other characteristic protected by law. Reasonable accommodations will be provided to applicants upon request.
Archer does not engage with external recruiting agencies without a prior written agreement. If you are a recruiting agency or individual recruiter, please contact People@archer.com. All employment processes are managed by the Archer People Team.
Seniority level
Mid-Senior level Employment type
Full-time Job function
Engineering and Information Technology Industries Airlines and Aviation Referrals increase your chances of interviewing at Archer by 2x
#J-18808-Ljbffr