Thermal Engineer, Electric Propulsion

Archer; San Jose (CA); On-site; USD 172,000 - 225,000; Full time

Job summary

Archer is seeking a Senior Thermal Engineer in San Jose, CA to develop and validate propulsion thermal models for an all-electric aircraft. You will design high-performance cooling solutions, run multi-physics analyses, and lead FAA-related thermal testing to verify performance.

You will collaborate with mechanical, software, and controls teams, build prototypes, and document results with clear engineering rationale to inform design decisions.

Qualifications

• BS / MS / PhD in Mechanical Engineering or Aerospace Engineering.
• 4+ years in thermal design and simulation in aerospace or automotive sectors.
• Strong heat transfer and flow physics knowledge: conduction, convection, radiation.
• Experience with power electronics, heat exchangers, and gearboxes.
• Proficient in MATLAB/Simulink and Python; Git version control.
• Experience with StarCCM+, Ansys Fluent, ICEpak and thermal tools.
• Ability to communicate complex technical rationale to multidisciplinary teams.
• Experience with lumped-parameter thermal networks, reduced-order modeling, Kalman filters.

Responsibilities

• Develop and maintain models for electric motors, inverters, thermal management, gearboxes, and power distribution.
• Create integrated multi-physics models coupling electrical, thermal, mechanical, and controls domains.
• Inform design decisions via analysis; lead trade studies for thermal solutions.
• Design high-performance thermal systems and build prototypes to verify performance.
• Build thermal test setups to measure temperatures, flowrates, and pressures.
• Plan and oversee thermal test campaigns, including FAA-related testing.
• Collaborate with engineers to define thermal boundary requirements and package within constraints.
• Coordinate with mechanical design to fit within vehicle volume and mass limits.
• Work with software/controls to develop embedded thermal models and observers.
• Document rationale, methodologies, and test results clearly.

Skills

Thermal design

Multiphysics modeling

MATLAB/Simulink

Python

Heat transfer fundamentals

Control theory basics

Kalman filters

Problem solving

Communication skills

Education

BS / MS / PhD in Mechanical or Aerospace Engineering

Tools

StarCCM+

Ansys Fluent

Ansys ICEpak

Thermal analysis packages

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

• 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.
• Use analysis to inform design decisions and optimize overall propulsion system performance. Lead trade studies evaluating design alternatives to determine optimal thermal solutions.
• Design creative high performance thermal systems, then build engineering prototypes to confirm performance.
• Design and build thermal test setups to measure system critical temperatures, flowrates, and pressures and confirm performance.
• Plan and oversee execution of thermal test campaigns validating your thermal models, including FAA certification testing related to the thermal system.
• Collaborate with other engineers to develop propulsion system thermal boundary requirements (external cooling flows, temperatures) and ensure propulsion system thermal design is optimized for vehicle level performance.
• Collaborate with mechanical design teams to package your thermal designs within the volume and mass constraints of the aircraft.
• Collaborate with Software and Controls teams to develop and implement embedded thermal models, observers, and overheat prevention.
• Clearly document and communicate thermal design rationale, analysis methodologies, and test results.
• Review measured thermal data from propulsion systems on Archer aircraft, confirm thermal systems are meeting performance requirements on aircraft

What You’ll Need

• BS / MS / PhD in Mechanical Engineering, or Aerospace Engineering
• 4+ years experience in thermal design and simulation, preferably within the aerospace or automotive sectors.
• Strong fundamentals and demonstrated understanding of heat transfer and flow physics, including, conduction, convection and radiation
• Experience with power electronics, electric motor, heat exchanger, and gearbox thermal design.
• Strong Experience in MATLAB/Simulink and Python (including object-oriented programming and version control via Git).
• Experience with industry-standard tools such as StarCCM+, Ansys Fluent, Ansys ICEpak and Thermal analysis packages,
• A systematic approach to problem-solving and the ability to communicate complex technical rationale to multidisciplinary stakeholders.
• Experience with lumped parameter thermal networks modeling, reduced-order modeling, kalman filters, control theory and application, and advanced signal processing.
• Experience with thermal testing and test-data correlation
• Self-motivated with ability to work independently and drive technical initiatives
• Strong written and verbal communication skills, experience writing technical reports.

Bonus Qualifications

• Prior experience with eVTOL aircraft
• Familiarity with FAA certification basis (Part 23/25 or 27/29)
• Experience with CAD modeling systems (e.g . NX, CATIA, Solidworks)
• Experience with embedded microcontroller software development in C
• Experience utilizing high-performance computing (HPC) to parallelize workflows
• Knowledge of simulation model validation, model calibration, and uncertainty quantification methods

Physical Requirements:

• Ability to work in laboratory and test environments
• May require occasional travel to test facilities

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 support the Company's strategy. For this position, we are targeting a base pay range of $172,000 - $225,000. 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 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.

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 to [e-mail]. All employment processes are managed by the Archer People Team.