Sr. Staff Design for Manufacturing 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. As a Staff DFM Engineer, you'll play a critical role in ensuring our printed circuit board assemblies (PCBAs) are optimized for manufacturability, reliability, and scalability in our revolutionary eVTOL aircraft. You'll be the bridge between design and production, driving manufacturing excellence while supporting Archer’s mission to transform urban transportation. What you’ll do: Lead PCBA manufacturing strategy for eVTOL applications, establishing scalable build processes from prototype to mass production. Qualify and verify manufacturing partners, evaluating technical capabilities, quality systems, and production capacity for both quick-turn prototypes and high-volume manufacturing. Develop and maintain DFM standards, creating comprehensive procedures, checklists, and best practices for rigid, flex, and rigid-flex PCB designs. Provide expert DFM guidance by reviewing PCBA designs and recommending optimizations to enhance manufacturability, yield, and cost-effectiveness. Drive process excellence at subcontractor sites by developing, implementing, and enforcing manufacturing procedures and quality standards. Conduct materials research and qualification through Design of Experiments (DoEs) to identify optimal materials for demanding eVTOL aerospace applications. Collaborate with eCAD librarians to develop component footprints that meet DFM requirements and manufacturing constraints. Lead root cause analysis for PCBA failures encountered during reliability testing and field operations, implementing corrective actions. Champion yield improvement initiatives at subcontractor assembly lines through data-driven problem solving. Partner cross-functionally with electrical engineering, mechanical engineering, program management, and product lifecycle teams to deliver exceptional results. What you need: BS Degree in Electrical, Mechanical, or Materials Science Engineering with 10+ years or MS with 6+ years of experience in related fields. Experience developing and implementing DFM processes for rigid, flex, and rigid-flex printed circuit board designs for aerospace, automotive, or industrial applications. A working knowledge of the materials, material properties, and processes used in PCBA manufacturing. A working knowledge of IPC‑610. Experience developing, deploying, and enforcing processes at subcontractor sites. Experience investigating and resolving issues encountered at subcontractor sites. Ability to travel frequently, ~20%. Excellent organizational and communication skills. Bonus Qualifications: Experience with Altium Designer. Experience in the development of RoHS compliant assemblies. Experience performing schematic capture for mixed signal, high voltage, and high power applications. Please note that this job description is intended to provide a general overview of the position and does not include an exhaustive list of responsibilities and qualifications. At Archer we aim to attract, retain, and motivate talent that possess the skills and leadership necessary to grow our business. We drive a pay‑for‑performance culture and reward performance that supports the Company’s business strategy. For this position we are targeting a base pay between $172,800 –$216,000. Actual compensation offered will be determined by factors such as job‑related knowledge, skills, and experience. Equal Opportunity Employer 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. Reasonable Accommodations 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 View email address on click.appcast.io. Reasonable accommodations will be determined on a case‑by‑case basis. Privacy and Non‑visa Sponsorship 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. Recruiting Policies Archer Aviation does not engage with external recruiting agencies or 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. All employment processes are managed by the Archer People Team. #J-18808-Ljbffr Archer