Staff Powertrain Manufacturing Engineer

About the Company

Archer is an aerospace company based in San Jose, California, building an all-electric vertical takeoff and landing (eVTOL) aircraft with a mission to advance the benefits of sustainable air mobility. We design, manufacture, and operate an all-electric aircraft that can carry four passengers while producing minimal noise. Our goal is to create scalable, cutting-edge technology, and we believe diversity in the workplace drives better insights and success.

About the Role

As part of Archer’s mission, we’re scaling production of our cutting-edge Electric Propulsion System (EPS) — the heart of our eVTOL aircraft. EPS comprises the Electric Motor, Inverter, and Propeller assemblies and represents one of the most technically demanding, highly automated manufacturing systems in our factory. We’re seeking a Powertrain Manufacturing Engineer experienced with electric motors and their integration into higher-level assemblies. This role is ideal for someone passionate about bridging design and production, creating scalable manufacturing systems, optimizing complex processes, and building world-class hardware from the ground up.

Responsibilities

• Contribute to the design and scaling of Archer’s Electric Propulsion System production line — from concept to high-rate manufacturing — including layout, automation strategy, tooling, and ramp-up planning.
• Collaborate cross-functionally with Product Design, Quality, Facilities, and Manufacturing teams to bring new electric motor and propeller systems into production.
• Lead Design for Manufacturability (DFM) efforts to ensure products are built efficiently, safely, and at scale.
• Develop and execute comprehensive manufacturing build plans — defining part flow, line layout, tools, equipment, and the manufacturing bill of materials (MBOM).
• Specify and validate automation systems, tooling, and test equipment to support high-reliability production.
• Perform PFMEA (Process Failure Mode & Effects Analysis) to proactively identify and mitigate risk in the production system.
• Author and approve detailed work instructions for EPS assembly and installation.
• Support first article builds and production validation testing to ensure process stability and repeatability.
• Drive continuous improvement through Lean, Six Sigma, and structured problem-solving methodologies.

Requirements

• Bachelor’s degree in Electrical, Mechanical, or Manufacturing Engineering (or equivalent).
• 7+ years of relevant experience in manufacturing engineering — preferably in EV, aerospace, or advanced hardware production.
• Experience building mechanical and electronic assemblies using sophisticated manufacturing tools and equipment.
• Hands-on experience with one of the following:
  • Thrust Assembly (or EPS) classified as the completed unit, integrating the electric engine with the propeller and miscellaneous parts.
  • Inverter production: sensitive electronic device assembly.
  • Rotor/stator/engine production: heavy machinery and pressing operations.
• Knowledge of CAD, PLM, MES, and ERP systems.
• Strong foundation in GD&T and statistical process control (SPC).
• Demonstrated ability to use structured problem-solving tools such as DMAIC, 8D, or 5 Whys.
• Well-developed communication and documentation skills — able to translate complex technical challenges into clear actions.
• Self-starter attitude with the ability to thrive in a fast-paced, highly regulated environment.

Preferred Qualifications

• Experience with EV Drive Unit (DU) manufacturing.
• Background in industrial automation (PLC, robotics, gantries).
• Familiarity with high-voltage systems, batteries, or electric motors.
• Knowledge of aircraft conformity or configuration management.
• Experience with NX and AutoCAD.
• Willingness to travel up to 10%.

Pay

For this position, we are targeting a base pay between $152,100 - $190,100. Actual compensation offered will be determined by factors such as job-related knowledge, skills, and experience.