Senior Mechanical Design Engineer: Electric Motor

Back to jobs New Senior Mechanical Design Engineer: Electric Motor San Jose, California, United States Apply 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. Our sights are set high and our problems are hard, and we believe that diversity in the workplace is what makes us smarter, drives better insights, and will ultimately lift us all to success. We are dedicated to cultivating an equitable and inclusive environment that embraces our differences, and supports and celebrates all of our team members. 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. Notable 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 At Archer we aim to attract, retain, and motivate talent that possess the skills and leadership necessary to grow our business. We drive a pay-for-performance culture and reward performance that supports the Company’s business strategy. 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. 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.   Information collected and processed as part of any job applications you choose to submit is subject to Archer's Candidate Privacy Policy . Archer is unable to provide work visa sponsorship for this position at the present time. Archer is proud to be an Equal Opportunity employer committed to diversity and inclusivity in the workplace. All aspects of employment are decided on the basis of merit, qualifications, and business needs. We do not discriminate based upon race, color, religion, sex, sexual orientation, age, national origin, disability status, protected veteran status, gender identity or any other characteristic protected by federal, state or local laws. Archer Aviation does not engage with external recruiting agencies/individual recruiters with whom it does not have a prior written agreement. Archer reserves the right to make use of any unsolicited resumes that it receives and bears no responsibility for payment of any fees asserted from the use of unsolicited resumes. If you are a recruiting agency or individual recruiter wishing to do business with Archer, please reach out to  People@archer.com . All employment processes are managed by the Archer People Team. 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