Senior Mechanical Engineer, Battery HV Distribution

Archer; San Jose (CA); On-site; USD 144,000 - 185,000; Full time

Job summary

Archer is seeking a Mechanical Design Engineer to advance high-voltage battery components within its next-gen aerospace platform. You will design enclosures, optimize HV power distribution, and ensure manufacturability across production phases.

Requirements include 5+ years of mechanical design experience, HV systems knowledge, and NX CAD proficiency, with a Bachelor’s in Mechanical/Aerospace engineering. This on-site role offers a base pay in a broad $144k–$185k range and a pay-for-performance

Qualifications

• Bachelor’s degree in Mechanical, Aerospace Engineering, or related field.
• 5+ years of mechanical design experience.
• Experience with HV systems and electric powertrains.
• Solid CAD / tolerance stack / GD&T; NX preferred.
• Experience from concept to high-volume production.
• Developed parts with manufacturing processes: laser welding, stamping, composites, adhesives, brazing, ultrasonic welding.
• Familiar with UN38.3, IEC, UL, and ISO HV battery standards.

Responsibilities

• Design and develop mechanical enclosures, mounts, and interfaces for high voltage battery components.
• Size power conductors, optimize insulation strategy, and interconnect strategy.
• Select high voltage contactors and perform fuse coordination studies for safe power distribution.
• Support high-voltage safety design practices, including creepage/clearance and shielding.
• Perform tolerance stack-ups, FEA simulations, and DFMEA to validate designs.
• Develop and release 2D drawings and 3D CAD models using NX.
• Manage and support prototype builds and validation testing, incorporating feedback into design cycles.
• Interface with manufacturing and supply chain to maintain design intent through production.

Skills

HV systems

Mechanical design

NX CAD

FMEA

Thermal design

Education

Bachelor’s degree in Mechanical or Aerospace Engineering

Tools

NX

CAE tools

Job description

Headquartered in Silicon Valley, California, Archer is a leader in the next-gen aerospace sector building an end-to-end advanced air mobility platform that delivers air taxis, unmanned aircraft systems (“UAS”), aviation-related physical artificial intelligence (“AI”) solutions, and other technologies to customers worldwide across the commercial aerospace and defense sectors.

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.

This role will play a key part in the design and integration of high-voltage components within our battery packs, contributing directly to the development of safe and efficient aircraft designs

What You’ll Do:

• Design and develop mechanical enclosures, mounts, and interfaces for high voltage battery components, ensuring structural integrity and manufacturability
• Size power conductors, optimize insulation strategy, and be responsible for interconnect strategy
• Select high voltage contactors and perform fuse coordination studies to ensure safe and reliable power distribution to and from battery packs
• Support high-voltage safety design practices, including creepage/clearance considerations, shielding, and sealing for HV components
• Perform detailed tolerance stack-ups, FEA simulations, and DFMEA to validate designs
• Develop and release 2D drawings and 3D CAD models using NX
• Manage and support prototype builds and validation testing, incorporating feedback into iterative design cycles
• Interface with manufacturing and supply chain partners to ensure design intent is maintained through production

What You Need:

• Bachelor’s degree in Mechanical, Aerospace Engineering, or a related field
• 5+ years of mechanical design experience
• Experience with HV systems and electric powertrains (bonus if hybrid)
• Automotive or aerospace experience is a plus but not required
• Expert understanding of efficient mechanical/thermal/electrical design.
• Knows how to use simplified tools, calculations, CAE to quickly drive development.
• Solid background in CAD / tolerance stack / GD&T (NX experience preferred)
• Experience going through the product development process from concept to high volume production.
• Developed parts with a number of manufacturing processes: laser welding, stamping, composites, adhesives, brazing, ultrasonic welding, fastening.
• Familiar with UN38.3, IEC, UL, and ISO standards as they pertain to HV batteries.

Please note that this job description is intended to provide a general overview of the position and does not include an exhaustive list of responsibilities and qualifications

At Archer we aim to attract, retain, and motivate talent that possess the skills and leadership necessary to grow our business. We drive a pay-for-performance culture and reward performance that supports the Company’s business strategy. For this position we are targeting a base pay between 144,000 - 185,000 Actual compensation offered will be determined by factors such as job-related knowledge, skills, and experienc

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 at [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.

Certain positions may be eligible for visa sponsorship.

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.