Senior Mechanical Design Engineer, Archer

• 5+ years of experience with electric motor design (aerospace, automotive, or other high-performance applications)
• Bachelor's degree in Mechanical Engineering, Electrical Engineering, or related field
• Demonstrated ability to design and analyze mechanical components and systems with a focus on electrical isolation, mechanical stress, thermal stress, chemical compatibility, and environmental durability
• Understanding of motor mechanical design fundamentals including:
• Laminated steel core design and manufacturing processes
• High-voltage insulation systems and dielectric strength requirements
• Creepage and clearance calculations per IEC/UL standards
• Experience designing plastic components for electrical systems, with knowledge of:
• Engineering polymers suitable for motor applications (PPS, PEEK, PA)
• Plastic injection molding design principles (wall thickness, draft angles, gate locations)
• Machined plastic component design and tolerancing
• Material selection for dielectric strength, temperature resistance, and mechanical stability
• Knowledge of GD&T and experience creating part and assembly drawings for manufacturing
• Proficiency in CAD software (NX preferred, Solidworks, Catia or Creo) for electromechanical assemblies
• Experience with at least two of the following:
• Laminated electrical steel stator and rotor cores
• High-voltage phase harnesses and busbar systems
• Wire wound stator assemblies and insulation systems
• Overmolded electrical components and assemblies
• Welded copper joints, high current applications
• Familiarity with motor manufacturing processes including core lamination, winding techniques, plastic molding, and assembly procedures
• Familiarity with PDM systems (Teamcenter preferred)
• Self-starter, team player, and desire to work in a fast-paced environment

Desirable

• Engineer critical motor components including phase harnesses, wye connections, insulation systems, and high-voltage busbars with focus on creepage and clearance requirements for aviation applications
• Design plastic components for motors including terminal housings, insulation barriers, and cooling system components, optimizing for both electrical and mechanical properties
• Design and develop mechanical aspects of permanent magnet synchronous motors from concept through manufacturing implementation
• Apply electromagnetic principles, thermal management, and mechanical stress analysis to create robust motor configurations including stator slot geometry, rotor assemblies, and insulation systems
• Implement design for manufacturing concepts to create motor designs that are cost effective, manufacturable, and high performance. Notable focus on insulated wire forming & stripping, laminated steel cores, plastic injection and overmolding, welded joints, and resin impregnation
• Contribute to company standards for motor component CAD models and drawings, including detailed specifications for insulation systems and HV safety requirements
• Collaborate with cross-functional teams including electromagnetics, thermal simulation, integrated test, quality, supply chain, safety, and manufacturing
• Support manufacturing & test to validate and verify that motor designs meet performance, safety, and certification requirements