Sr Staff Modeling Engineer - Powertrain

Sr Staff Modeling Engineer - Powertrain San Jose, California, United States Apply 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: Modeling Architecture & Development Design and implement comprehensive modeling architectures for electric powertrain systems spanning multiple fidelity levels (low-order physics-based to including high-fidelity FEA) 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 Establish modeling standards, unit tests, best practices, and validation protocols across the powertrain team Design, develop and deploy a robust automation framework to streamline simulation, analysis and benchmarking of powertrain models with test data Optimization & Simulation Develop and deploy advanced optimization strategies including genetic algorithms, gradient-based methods, and multi-objective optimization frameworks Interface optimization routines with vehicle-level simulation tools to evaluate system-level performance trades Create efficient parametric models enabling rapid design space exploration Implement surrogate modeling and reduced-order modeling techniques for computationally expensive analyses Technical Integration & Leadership Serve as technical liaison between powertrain modeling, vehicle simulation team, and EEC (Electronic Engine Control) software developers Define interface requirements and data exchange protocols between subsystem models and vehicle-level simulations Collaborate with controls engineers to integrate motor control algorithms and power management strategies into system models Lead model validation activities against test data and guide instrumentation requirements Analysis & Innovation Perform sensitivity analyses and uncertainty quantification to guide robust design decisions Drive innovation in modeling methodologies to reduce computational time while maintaining accuracy Develop digital twin frameworks for predictive maintenance and performance monitoring What You Need: Master's or Ph.D. in Mechanical Engineering, Electrical Engineering, Aerospace Engineering, or related field 8+ years of experience in modeling and simulation with at least 3 years in a senior technical role Expert-level proficiency in MATLAB/Simulink and Python for modeling and analysis Strong software engineering skills including version control (Git), object-oriented programming, and code architecture Proven ability to develop both high-fidelity and reduced-order models appropriate for different design phases Deep knowledge of optimization techniques including genetic algorithms, particle swarm, simulated annealing, and gradient-based methods Professional Skills Demonstrated leadership in technically complex projects with cross-functional teams Excellent communication skills with ability to explain complex technical concepts to diverse audiences Strategic thinking with ability to balance high-fidelity accuracy with computational efficiency Self-motivated with ability to work independently and drive technical initiatives Understanding of controls systems and ability to integrate control strategies into plant models Experience with certification and airworthiness requirements (strong plus) Bonus Requirements: Previous experience in aerospace, eVTOL, or electric vehicle industries Publications or patents in powertrain modeling or optimization Background in electric powertrain systems including: Electric motor design and performance modeling (PMSM, induction, etc.) Power electronics and inverter operation Thermal management systems and heat transfer Gearbox and mechanical drivetrain modeling Battery systems and energy storage (plus) Experience with FEA tools (ANSYS, COMSOL, or equivalent) for multi-physics analysis Experience with Model-Based Systems Engineering (MBSE) tools Knowledge of DO-178C or similar safety-critical software standards Familiarity with real-time simulation and hardware-in-the-loop (HIL) testing Experience with high-performance computing and cloud-based simulation platforms Background in certification and qualification of models for aerospace applications