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Archer · 1 day ago

Staff Design Engineer - Gearbox, Advanced Projects

San Jose, CA

Full-time

Onsite

Lead/Staff

$163K/yr - $204K/yr

8+ years exp

Archer is an aerospace company based in San Jose, California, focused on developing all-electric vertical takeoff and landing aircraft. The Staff Design Engineer will lead the design and development of gearbox systems, ensuring the performance and reliability of electric propulsion systems while mentoring junior engineers and collaborating across teams.

AerospaceAir TransportationElectric VehicleManufacturing

No H1B

Responsibilities

Lead design and development of complex gearbox systems from concept through production

Perform trade studies to optimize system mass, durability, and efficiency

Support detailed designs of gears, shafts, bearings, and seals

Develop lubrication requirements to support gear and bearing performance

Create and review CAD models, technical drawings, and specifications

Work with vendors to incorporate DFM feedback and ensure parts can be manufactured to specifications

Perform gear and bearing analysis using ISO calculations and FEA

Help develop test plans and test fixtures to validate components

Analyze test data and implement design improvements based on findings

Serve as the primary technical expert for triaging and resolving critical issues during the design/development cycle

Lead by example, actively designing alongside the team while providing technical oversight

Mentor and/or oversee junior engineers

Work with systems, safety, and reliability teams to inform DFMEA and ensure requirements are properly validated and understood

Drive cross-functional project teams including manufacturing, quality, sourcing, and test engineering

Lead design reviews and provide technical expertise for critical decisions

Qualification

Gearbox designCAD modelingFEA analysisRotorcraft experienceMaterial selectionLubrication methodsTransmission testingBOM managementCommunication skillsLeadership skillsAttention to detail

Required

Bachelor's Degree in mechanical engineering, physics, or related field

Minimum of 8-12+ years of rotorcraft gearbox design experience

Proven experience with gear specification, material selection, heat treatments, shaft layouts, bearing selection, spline rating, housing design, seal selection, and lubrication methods

Experience with transmission and driveline testing procedures (aircraft or dynamometer)

Experience generating Bills of Materials (BOM) and managing change control processes

Proficiency in CAD modeling (NX preferred), 2D drawings, tolerance analysis, and GD&T

Familiarity with FEA software packages (ANSYS, NASTRAN, and Romax preferred) to analyze gear and bearing components

Knowledge of manufacturing processes for gearbox components

Proven ability to organize and lead cross-functional technical initiatives

Excellent presentation and communication skills to influence decision-making

Capacity to translate complex technical concepts for diverse audiences

Availability for domestic travel as needed

Demonstrated commitment to safety and quality in engineering practices