Mechanical Design Engineer - Thermal and Ducting

The role

This person will design thermal and ducting integration solutions for powertrain components on prototype aircraft. They will develop hardware, select thermal management components, and own the prototype development process.

What you will do

• Design thermal and ducting integration solutions for powertrain components on prototype aircraft
• Collaborate with aerothermal analysts to optimize duct designs
• 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 to ensure proper integration of all systems
• Own the prototype development process including requirements, design, BOM, procurement, assembly, and test
• Complete handbook calculations to verify system performance and component margins
• Interface with suppliers to select COTS solutions
• Develop verification testing strategies and see designs through testing

Required qualifications

• 5+ years of engineering experience
• Bachelor's degree in Mechanical Engineering
• Exposure to integrating thermal systems or air breathing turbomachinery
• Proficient in CAD (Solidworks, NX, etc.)
• 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

Nice to have

• 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

About the company

Archer is a leader in the next-gen aerospace sector building an end-to-end advanced air mobility platform. They deliver air taxis, unmanned aircraft systems, aviation-related physical artificial intelligence solutions, and other technologies to customers worldwide.