Sr Staff Modeling Engineer - Powertrain

Archer; San Jose (CA); On-site; USD 177,000 - 226,000; Full time

Job summary

Archer, an aerospace company in San Jose, CA, seeks a senior modeling and simulation leader to design comprehensive powertrain models and an automation framework for fast design-space exploration. You will drive multi-physics integration, validate against test data, and collaborate with vehicle simulation and ECUs teams.

The role requires 8+ years in modeling, expertise in MATLAB/Simulink and Python, and strong software engineering skills.

Qualifications

• Master's or PhD in Mechanical, Electrical, Aerospace Engineering, or related field.
• 8+ years of modeling and simulation experience; at least 3 years in a senior technical role.
• Expert-level MATLAB/Simulink and Python for modeling and analysis.
• Strong software engineering skills including version control (Git), OO programming, and code architecture.
• Proven ability to develop both high-fidelity and reduced-order models for different design phases.
• Deep knowledge of optimization techniques (genetic algorithms, particle swarm, simulated annealing, gradient-based methods).

Responsibilities

• Design and implement modeling architectures for powertrain systems across fidelity levels.
• Develop and maintain models for motors, inverters, thermal management, gearboxes, and power distribution.
• Create multi-physics models coupling electrical, thermal, mechanical, and controls domains.
• Establish modeling standards, tests, and validation protocols for the powertrain team.
• Build an automation framework to streamline simulation, analysis, and benchmarking with test data.
• Serve as liaison between powertrain modeling, vehicle simulation, and ECU software teams.
• Define interfaces and data exchange between subsystem models and vehicle simulations.
• Collaborate with controls engineers to integrate motor control algorithms into models.
• Lead model validation activities against test data and guide instrumentation requirements.
• Perform sensitivity analyses and uncertainty quantification to guide design decisions.
• Drive modeling methodological innovation to reduce compute time while maintaining accuracy.
• Develop digital twin frameworks for predictive maintenance and performance monitoring.

Skills

Leadership

Communication

Strategic thinking

Independent work

Education

Master's or PhD in Engineering

Tools

MATLAB/Simulink

Python

Git

Job description

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:

Modeling Architecture & Development

• Design and implement comprehensive modeling architectures for electric powertrain systems spanning multiple fidelity levels (low-order physics-based to including high-fidelity FEA)
• Develop and maintain models for electric motors, inverters, thermal management systems, gearboxes, and power distribution systems
• Create integrated multi-physics models coupling electrical, thermal, mechanical, and controls domains
• Establish modeling standards, unit tests, best practices, and validation protocols across the powertrain team
• Design, develop and deploy a robust automation framework to streamline simulation, analysis and benchmarking of powertrain models with test data

Optimization & Simulation

• Develop and deploy advanced optimization strategies including genetic algorithms, gradient-based methods, and multi-objective optimization frameworks
• Interface optimization routines with vehicle-level simulation tools to evaluate system-level performance trades
• Create efficient parametric models enabling rapid design space exploration
• Implement surrogate modeling and reduced-order modeling techniques for computationally expensive analyses

Technical Integration & Leadership

• Serve as technical liaison between powertrain modeling, vehicle simulation team, and EEC (Electronic Engine Control) software developers
• Define interface requirements and data exchange protocols between subsystem models and vehicle-level simulations
• Collaborate with controls engineers to integrate motor control algorithms and power management strategies into system models
• Lead model validation activities against test data and guide instrumentation requirements

Analysis & Innovation

• Perform sensitivity analyses and uncertainty quantification to guide robust design decisions
• Drive innovation in modeling methodologies to reduce computational time while maintaining accuracy
• Develop digital twin frameworks for predictive maintenance and performance monitoring

What You Need:

• Master's or Ph.D. in Mechanical Engineering, Electrical Engineering, Aerospace Engineering, or related field
• 8+ years of experience in modeling and simulation with at least 3 years in a senior technical role
• Expert-level proficiency in MATLAB/Simulink and Python for modeling and analysis
• Strong software engineering skills including version control (Git), object-oriented programming, and code architecture
• Proven ability to develop both high-fidelity and reduced-order models appropriate for different design phases
• Deep knowledge of optimization techniques including genetic algorithms, particle swarm, simulated annealing, and gradient-based methods

Professional Skills

• Demonstrated leadership in technically complex projects with cross-functional teams
• Excellent communication skills with ability to explain complex technical concepts to diverse audiences
• Strategic thinking with ability to balance high-fidelity accuracy with computational efficiency
• Self-motivated with ability to work independently and drive technical initiatives
• Understanding of controls systems and ability to integrate control strategies into plant models
• Experience with certification and airworthiness requirements (strong plus)

Bonus Requirements:

• Previous experience in aerospace, eVTOL, or electric vehicle industries
• Publications or patents in powertrain modeling or optimization
• Background in electric powertrain systems including:
  • Electric motor design and performance modeling (PMSM, induction, etc.)
  • Power electronics and inverter operation
  • Thermal management systems and heat transfer
  • Gearbox and mechanical drivetrain modeling
  • Battery systems and energy storage (plus)
• Experience with FEA tools (ANSYS, COMSOL, or equivalent) for multi-physics analysis
• Experience with Model-Based Systems Engineering (MBSE) tools
• Knowledge of DO-178C or similar safety-critical software standards
• Familiarity with real-time simulation and hardware-in-the-loop (HIL) testing
• Experience with high-performance computing and cloud-based simulation platforms
• Background in certification and qualification of models for aerospace applications

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 $176,800.00 - $226,000.00. Actual compensation offered will be determined by factors such as job-related knowledge, skills, and experience.

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 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.