Sr. Manufacturing Design Engineer - eMotor

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

We’re scaling production of our High Voltage Electric Propulsion System — the heart of our eVTOL aircraft, which includes the High Voltage Battery, Electric Motor and Propeller assemblies and represents one of the most technically demanding, highly automated manufacturing systems in our factory. We are seeking a deeply technical, hands-on Sr. Manufacturing Design Engineer to serve as the primary bridge between R&D product design and physical production execution. In this role, you will lead complex electric propulsion hardware (stators, rotors, housings, gearboxes) through its full evolution—from early-stage prototyping to repeatable, scalable mass production. You will thrive in high-ownership environments, applying structured engineering principles to solve complex manufacturing challenges under tight schedules. Your primary focus will be establishing, validating, and optimizing production systems for the EPS across multiple aircraft programs.

Responsibilities

• Design for Manufacturability (DFM): Spearhead DFM/DFA initiatives, collaborating with cross-functional teams (Product Design, Quality, Facilities) to optimize electric powertrain system (EPS) manufacturability.
• NPI & Prototype Execution: Lead initial prototype build plans, execute process trials, develop custom tooling, and drive system builds through equipment qualification and production ramp-up.
• Automation & Tooling Specs: Define technical specifications for automation equipment, tools, and custom fixtures, managing vendor development through final Acceptance Testing (FAT/SAT).
• Line Design & MBOM Development: Develop comprehensive build plans, including plant line layouts, optimized part flow, manufacturing methods, and accurate Manufacturing Bills of Materials (MBOM).
• Quality & Process Control: Conduct PFMEAs, establish validation/calibration protocols, and author standardized work instructions to ensure zero-defect assembly.
• OEE & Continuous Improvement: Monitor pilot line performance, drive Root Cause Corrective Actions (RCCA), and optimize cycle times for mass production readiness.

Requirements

• Bachelor’s degree in Mechanical, Manufacturing, or Electrical Engineering with 3–6+ years of hands-on experience (EV, Automotive, or Aerospace preferred).
• Direct experience building and troubleshooting mechanical and electronic assemblies using advanced automated manufacturing equipment.
• Proven expertise in Statistical Process Control (SPC), Geometric Dimensioning and Tolerancing (GD&T), and drawing reviews.
• Demonstrated track record of scaling production lines from early prototype builds through high-volume mass production.
• Proficiency using formal methodologies (Lean, Six Sigma, DMAIC, 8D, 5-Why) to resolve high-level equipment and process performance issues.
• Daily working proficiency with CAD (e.g., NX, AutoCAD), PLM, MES, and ERP systems.
• Exceptional written and verbal communication skills with the resilience to thrive in a fast-paced, highly regulated, and dynamic environment.

Skills

• eMotor & Drive Unit Expertise: Direct hands-on manufacturing experience with EV Drive Units (DU), specifically rotor, stator, or gearbox assembly processes.
• Industrial Automation: Hands-on experience programming and troubleshooting industrial robotics, gantries, and PLCs.
• High Voltage Systems: Knowledge of high-voltage (HV) wiring, battery modules, and electric motor safety standards.
• Aerospace Compliance: Familiarity with eVTOL systems, aircraft configuration management, and airworthiness conformity processes.
• Maintenance & Reliability: Experience establishing Preventive/Predictive Maintenance programs and driving Overall Equipment Effectiveness (OEE) improvements.
• Willingness to travel up to 10% for vendor oversight and equipment integration.

Pay

For this position we are targeting a base pay between $126,700 - $158,400. Actual compensation offered will be determined by factors such as job-related knowledge, skills, and experience.