Senior Mechanical Engineer, Battery HV Distribution

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.

About the role

This role will play a key part in the design and integration of high-voltage components within our battery packs, contributing directly to the development of safe and efficient aircraft designs.

Responsibilities

• Design and develop mechanical enclosures, mounts, and interfaces for high voltage battery components, ensuring structural integrity and manufacturability
• Size power conductors, optimize insulation strategy, and be responsible for interconnect strategy
• Select high voltage contactors and perform fuse coordination studies to ensure safe and reliable power distribution to and from battery packs
• Support high-voltage safety design practices, including creepage/clearance considerations, shielding, and sealing for HV components
• Perform detailed tolerance stack-ups, FEA simulations, and DFMEA to validate designs
• Develop and release 2D drawings and 3D CAD models using NX
• Manage and support prototype builds and validation testing, incorporating feedback into iterative design cycles
• Interface with manufacturing and supply chain partners to ensure design intent is maintained through production

Requirements

• Bachelor’s degree in Mechanical, Aerospace Engineering, or a related field
• 5+ years of mechanical design experience
• Experience with HV systems and electric powertrains (bonus if hybrid)
• Automotive or aerospace experience is a plus but not required
• Expert understanding of efficient mechanical/thermal/electrical design. Knows how to use simplified tools, calculations, CAE to quickly drive development
• Solid background in CAD / tolerance stack / GD&T (NX experience preferred)
• Experience going through the product development process from concept to high volume production
• Developed parts with a number of manufacturing processes: laser welding, stamping, composites, adhesives, brazing, ultrasonic welding, fastening
• Familiar with UN38.3, IEC, UL, and ISO standards as they pertain to HV batteries

Pay

For this position we are targeting a base pay between $144,000 - $185,000. Actual compensation offered will be determined by factors such as job-related knowledge, skills, and experience.