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Design Engineer, Thermal and Lubrication

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.

As a Senior Design Engineer on our Thermal Lubrication System team, you'll play a critical role in developing advanced lubrication and thermal management systems that ensure optimal performance and reliability of Archer's electric propulsion technology. This position combines deep technical expertise in fluid systems design with hands-on development experience to create innovative solutions that push the boundaries of electric aviation performance.

What You'll Do:

  • System Design and Development
    • Lead design and development of integrated thermal lubrication systems from initial concept through production implementation
    • Design and specify pumps, filters, heat exchangers, pressure relief valves, and related system components
    • Develop system architectures that optimize thermal management and lubrication performance
    • Create detailed CAD models, technical drawings, and system specifications
    • Collaborate with manufacturing teams to ensure designs are optimized for production
  • Analysis and Modeling
    • Perform 1D system modeling and simulation using tools such as GT-Power, AMESim, or MATLAB/Simulink
    • Conduct thermal and fluid flow analysis to validate system performance
    • Utilize CFD analysis (StarCCM+ preferred) to optimize component and system designs
    • Develop and maintain system performance models for various operating conditions
    • Support trade studies to balance system performance, weight, and packaging requirements
  • Testing and Validation
    • Design and develop custom lubrication test equipment and fixtures
    • Plan and execute component and system-level testing programs
    • Operate test equipment and analyze results to validate design performance
    • Lead troubleshooting efforts and implement design improvements based on test findings
    • Support certification testing requirements and documentation
  • Technical Leadership and Collaboration
    • Provide technical guidance and mentorship to junior engineers
    • Interface with cross-functional groups including propulsion unit design, manufacturing, aerodynamics, and development test teams
    • Support design reviews and provide expert technical recommendations
    • Drive supplier relationships and technical discussions for key components
    • Contribute to DFMEA processes and reliability assessments

What You Need:

  • Education & Experience
    • Bachelor's Degree in Mechanical Engineering, Aerospace Engineering, or related technical field
    • Minimum of 5+ years of experience in fluid systems, lubrication systems, or thermal management design
    • Proven track record of taking systems from concept through production
  • Technical Expertise
    • Proficiency in CAD modeling software (NX, Creo, or similar) and 2D drawings
    • Strong experience with 1D modeling tools such as GT-Power, AMESim, or MATLAB/Simulink
    • Understanding of fluid mechanics, heat transfer, and thermodynamics principles
    • Knowledge of manufacturing processes for fluid system components
  • Communication and Problem-Solving
    • Strong analytical and problem-solving skills with attention to detail
    • Excellent written and verbal communication skills
    • Ability to work effectively in a fast-paced, collaborative environment
    • Self-motivated with ability to manage multiple projects simultaneously
  • Additional Requirements
    • Willingness to travel as needed for testing and supplier visits
    • Commitment to safety-first engineering practices

Bonus Qualifications:

  • CFD experience with StarCCM+ or similar software packages
  • Aerospace or aviation industry development experience
  • Experience with lubricant formulation and development
  • Knowledge of aerospace certification processes (FAA/EASA)
  • Experience with electric vehicle or hybrid vehicle lubrication systems
  • Advanced degree in relevant engineering discipline
  • Experience with data acquisition systems and test automation

 

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 people@archer.com. 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 People@archer.com. All employment processes are managed by the Archer People Team.

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