Mechanical Design Engineer - Thermal and Ducting

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

Mechanical Design Engineer - Thermal and Ducting

San Jose, California, United States

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.

Our sights are set high and our problems are hard, and we believe that diversity in the workplace is what makes us smarter, drives better insights, and will ultimately lift us all to success. We are dedicated to cultivating an equitable and inclusive environment that embraces our differences, and supports and celebrates all of our team members.

What You’ll Do:

• Design thermal and ducting integration solutions for powertrain components on prototype aircraft including: generators and turboshaft engines
• Turn theoretical thermal solutions into real hardware by collaborating 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 on aircraft
• 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 closely with powertrain engineers and airframe team to ensure proper integration of all systems
• Own the prototype development process; requirements, design, BOM, procurement, assembly, test, etc.
• Complete handbook calculations to verify system performance and component margins
• Interface with suppliers to select COTS solutions where appropriate
• Develop verification testing strategies and see your designs through rigorous process intensive testing (DO-160G, etc.)
• Create and review technical drawings, plans, and specifications
• Support requirements development and documentation

What You Need:

• 5+ years of engineering experience
• Bachelor's degree in Mechanical Engineering
• 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, etc.)
• Experience designing metallic parts including machined components, sheet metal, and weldments
• Fluent in GD&T and creating manufacturing drawings
• Hands-on experience in multiple technical fields especially those related to carbon composite, sheet metal ducting, and metallic structures

Bonus Qualifications:

• Bachelor’s degree in Aerospace, Mechanical, or Electrical Engineering (or equivalent)
• Knowledge of, and experience within, electric powertrain systems or aerospace systems.
• Thorough understanding of engineering product development including design phases, manufacturing processes and global supply chain management.
• Familiarization with Atlassian Jira and Confluence for task management and collaborative documentation.
• Experience supporting vehicle development from concept/prototype aircraft phase through certification and mass production

At Archer, we aim to attract, retain, and motivate talent with the skills and leadership needed to grow our business. We drive a pay-for-performance culture and reward performance that supports the Company’s strategy. For this position, we are targeting a base pay range of $144,000 - $198,000. Actual compensation offered will be determined by job-related knowledge, skills, and experience.

Archer is committed to working with and providing reasonable accommodations to job applicants with physical or mental disabilities, and those with sincerely held religious beliefs. Applicants who may require reasonable accommodation for any part of the application or hiring process should provide their name and contact information to Archer’s People Team [e-mail] . Reasonable accommodations will be determined on a case-by-case basis.

Information collected and processed as part of any job applications you choose to submit is subject to Archer's Candidate Privacy Policy .

Archer is unable to provide work visa sponsorship for this position at the present time.

Archer is proud to be an Equal Opportunity employer committed to diversity and inclusivity in the workplace. All aspects of employment are decided on the basis of merit, qualifications, and business needs. We do not discriminate based upon race, color, religion, sex, sexual orientation, age, national origin, disability status, protected veteran status, gender identity or any other characteristic protected by federal, state or local laws.

Archer Aviation does not engage with external recruiting agencies/individual recruiters with whom it does not have a prior written agreement. Archer reserves the right to make use of any unsolicited resumes that it receives and bears no responsibility for payment of any fees asserted from the use of unsolicited resumes. If you are a recruiting agency or individual recruiter wishing to do business with Archer, please reach out [e-mail] . All employment processes are managed by the Archer People Team.