Aerospace Thermal & Ducting Design Engineer (Prototype)

Archer; San Jose (CA); On-site; USD 144,000 - 198,000; Full time

Job summary

Archer seeks a Mechanical Design Engineer - Thermal and Ducting in San Jose, CA to design and integrate thermal management solutions for prototype aircraft powertrains. You will work with aerothermal analysts to optimize duct systems, select pumps and sensors, and ensure compatibility with structural teams.

The role emphasizes hands-on development from concept through BOM, procurement, assembly, and testing, with an emphasis on DO-160G compliant verification and supplier collaboration.

Qualifications

• Requires a Bachelor's degree in Mechanical Engineering and 5+ years of engineering experience.
• Exposure to integrating thermal systems or air breathing turbomachinery.
• Ability to manage CAD and complex assemblies in Team Center.
• Familiarity with aerospace hardware and fastener standards.
• Proficient in FEA using professional tools (NASTRAN, ANSYS, Abaqus).

Responsibilities

• Design thermal and ducting integration solutions for powertrain components on prototype aircraft.
• Collaborate with aerothermal analysts to optimize duct designs for performance, pressure drop, and thermal efficiency.
• Design inlet and exhaust ducting systems for turboshaft engines and thermal management systems.
• Select and integrate thermal management components including pumps, lines, fittings, and sensors.
• Collaborate with structural analysts to ensure designs meet strength, stiffness, and fatigue requirements.
• Work with powertrain engineers and airframe team for proper system integration.
• Own the prototype development process; requirements, design, BOM, procurement, assembly, test.
• Create verification calculations to verify system performance and margins.
• Interface with suppliers to select COTS solutions where appropriate.
• Develop verification testing strategies and execute rigorous tests (DO-160G).
• Create and review technical drawings, plans, and specifications.

Skills

Thermal systems integration

TeamCenter CAD management

Aerospace hardware familiarity

GD&T proficiency

FEA (NASTRAN/ANSYS/Abaqus)

Education

Bachelor's degree in Mechanical Engineering

Tools

TeamCenter

NASTRAN

ANSYS

Abaqus

Job description

Archer seeks a Mechanical Design Engineer - Thermal and Ducting in San Jose, CA to design and integrate thermal management solutions for prototype aircraft powertrains. You will work with aerothermal analysts to optimize duct systems, select pumps and sensors, and ensure compatibility with structural teams.

The role emphasizes hands-on development from concept through BOM, procurement, assembly, and testing, with an emphasis on DO-160G compliant verification and supplier collaboration.