Battery Manufacturing Design Engineer

Position: Staff Battery Manufacturing Design Engineer
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.

About The Team:

At Archer, we're scaling production of the high-voltage battery systems that power our next-generation eVTOL aircraft. As a Staff Battery (HVPS) Manufacturing Design Engineer, you will lead the design, development, and launch of advanced manufacturing lines for Archer's Battery Pack and Module production. This role combines deep manufacturing engineering expertise with strong program leadership, driving equipment specifications, process development, automation strategy, factory readiness, and production ramp activities for one of the most critical systems in the aircraft.

We're seeking a highly technical and hands-on manufacturing engineer with experience developing and launching complex battery or high-voltage manufacturing lines in high-volume production environments. A major part of this role will focus on project management, team leadership, and cross-functional execution, including mentoring engineers and driving alignment across Manufacturing, Design Engineering, Supply Chain, Quality, Facilities, and Production teams. The ideal candidate thrives in fast-paced development programs, brings strong equipment and process development expertise, and has a proven track record of scaling advanced manufacturing operations from concept through launch.

What You'll Do:

* Partner with Archer's Battery Module and Pack Manufacturing Engineering team to scale production from prototype builds through high-volume series manufacturing

* Collaborate cross-functionally with Product Design Engineering, Test, Quality, Supply Chain, and Production teams to launch and optimize flight worthy battery pack manufacturing systems

* Own multiple manufacturing stations and processes including process development, process controls, operator training, troubleshooting process deviations, and driving Design for Manufacturability (DFM) improvements

* Develop and improve manufacturing workflows, tooling, fixtures, workstations, and ergonomic solutions to optimize line efficiency, product flow, safety, and cost using Lean and 5S methodologies

* Drive process capability and quality performance through PFMEA development, statistical process control, KPI tracking, and continuous improvement initiatives.

* Support Material Review Board (MRB) activities and disposition of non-conforming products and manufacturing processes

* Support supplier development, procurement activities, production readiness, and day-to-day shop floor operations to identify risks and drive operational performance

What You Need:

* Education:

Bachelor's degree in Mechanical, Electrical, Manufacturing Engineering, or a related technical discipline; advanced degree preferred

* Experience:

7+ years of experience in manufacturing engineering, automation, or advanced production environments, including 2+ years directly supporting EV battery module or pack manufacturing from prototype through high-volume production

* Strong hands-on experience supporting both prototype and high-volume manufacturing operations for complex electromechanical or high-voltage assemblies

* Deep expertise in battery manufacturing processes such as adhesive dispensing, cell testing, potting, pick-and-place automation, and high-voltage electrical testing.

* Strong foundation in Lean Manufacturing, Six Sigma (DMAIC), APQP methodologies, PFMEA development, SPC, MSA, and GD&T

* Experience integrating and supporting industrial manufacturing equipment including dispense systems, torque tools, power transducers, PLCs, robotics, motion control systems, and machine safety devices

* Experience with CAD, PLM, MES, and ERP systems, along with data analysis and visualization tools such as SQL, Python, Tableau, or similar platforms

* Knowledge of applicable electrical and safety standards including NFPA
79, NEC, UL508A, ANSI/RIA
15.06, and OSHA requirements

* Demonstrated experience leading DOE planning, experimentation, statistical analysis, and manufacturing process validation activities

* Excellent communication, organizational, and cross-functional leadership skills with the ability to thrive in a fast-paced manufacturing environment

Bonus

Qualifications:

* Experience supporting aerospace, EV, or other highly regulated advanced manufacturing environments

* Familiarity with FAA regulations including FAR Part 23, Part 21, or Production Certificate requirements

*…