Aero-Structures Engineer

Green Aero Propulsion; Bengaluru; On-site; INR 1,200,000 - 2,400,000; Full time

Job summary

Green Aero Propulsion is seeking an experienced engineer for the Aero-Structures & Mechanisms team in Bengaluru to design airframe structures and deployment systems for flight hardware. You will run hand calculations and FEA, develop mechanisms, define load paths, and work with propulsion and avionics on interfaces and mass budgets.

The role requires strong fundamentals in aircraft structures, CAD/FEA tools, and hands-on project experience with UAV/rocket systems or related theses.

Qualifications

• B.Tech / M.Tech / M.E. / M.Sc. in Aerospace, Mechanical, Aeronautical, Mechatronics, Materials or a related discipline.
• Strong fundamentals in mechanics of materials, aircraft structures (thin-walled beams, buckling), machine design and composites.
• Understanding of mechanism design: linkages, latches, springs, friction, tolerances and fits.
• Working knowledge of at least one CAD package (CATIA, SolidWorks, NX, Creo or Fusion).
• Working knowledge of at least one FEA tool (Ansys, Abaqus, Nastran/Patran, Hypermesh or similar).
• Ability to do hand calculations and sanity-check numerical output.
• Clear technical writing and communication.
• Hands-on project experience in UAV/rocket-related teams or thesis work in structures or mechanisms.
• Exposure to recovery systems, release devices, or safety-critical mechanisms.
• Scripting in Python or MATLAB, and test experience with strain gauges, load cells and DAQ.

Responsibilities

• Design airframe structures (fuselage, wing, empennage, joints, fittings, hatches and mounts) in composites and metals, to meet targets.
• Design and develop mechanisms for the vehicle, including hold-and-release and deployment systems.
• Define load cases and derive load paths through structures and mechanisms.
• Run hand calculations and FEA for strength, buckling, fatigue and stiffness, cross-checking results.
• Analyse mechanisms for kinematics, tolerances and failure modes (FMEA).
• Design and analyse bolted, bonded and fastened joints and local load-introduction features.
• Work on composite layup design, material selection and manufacturing processes.
• Select and integrate actuators and release devices, and work with avionics on commands and interlocks.
• Plan and run structural and mechanism tests and correlate results with analysis.
• Prepare drawings, GD&T, BOMs, stress reports and test reports for certification and range-safety review.
• Collaborate with propulsion, avionics, recovery and flight-test teams on interfaces and mass budgets.
• Support assembly, integration, flight-test operations and root-cause analysis of anomalies.

Skills

Mechanics of materials

Aircraft structures

Mechanism design

Hand calculations

Python scripting

Matlab scripting

Clear technical writing

Education

B.Tech / M.Tech / M.E. / M.Sc. (Engg.) in Aerospace, Mechanical, Aeronautical, Mechatronics, Materials

Tools

CATIA

SolidWorks

NX

Creo

Fusion

Ansys

Abaqus

Nastran/Patran

Hypermesh

Job description

Department: Aero-Structures & Mechanisms

Employment Type: Full-Time (Fully On-Site)

Key responsibilities

• Design airframe structures (fuselage, wing, empennage, joints, fittings, hatches and mounts) in composites and metals, to meet strength, stiffness, weight and manufacturability targets.
• Design and develop mechanisms for the vehicle, including hold-and-release, parachute deployment and other latching, separation and deployment systems.
• Define load cases (flight, ground handling, launch, landing, recovery) and derive load paths through structures and mechanisms.
• Run hand calculations and FEA for strength, buckling, fatigue and stiffness, and cross-check FEA against analytical estimates.
• Analyse mechanisms for kinematics, friction, tolerance stack-ups, release and deployment loads, and failure modes (FMEA).
• Design and analyse bolted, bonded and fastened joints and local load-introduction features, such as engine mounts, attachment points and payload interfaces.
• Work on composite layup design, material selection and allowables, and on manufacturing processes (wet layup, prepreg, vacuum bagging, machining).
• Select and integrate actuators and release devices, and work with avionics on commands and interlocks.
• Plan and run structural and mechanism tests: coupon, sub-component, proof load, repeatability, functional and deployment trials. Correlate the results with analysis.
• Prepare drawings, GD&T, BOMs, stress reports and test reports to a standard that supports certification and range-safety review.
• Work with propulsion, avionics, recovery and flight-test teams on interfaces and mass budgets.
• Support assembly, integration, flight-test operations and root-cause analysis of any structural or mechanism anomaly.

Required qualifications

• B.Tech / M.Tech / M.E. / M.Sc. (Engg.) in Aerospace, Mechanical, Aeronautical, Mechatronics, Materials or a related discipline.
• Strong fundamentals in mechanics of materials, aircraft structures (thin-walled beams, buckling), machine design and composites.
• Understanding of mechanism design: linkages, latches, springs, friction, tolerances and fits.
• Working knowledge of at least one CAD package (CATIA, SolidWorks, NX, Creo or Fusion).
• Working knowledge of at least one FEA tool (Ansys, Abaqus, Nastran/Patran, Hypermesh or similar).
• Ability to do hand calculations and sanity-check numerical output.
• Clear technical writing and communication.
• Preferred (not mandatory)
• Hands-on project experience in a UAV, rocket, satellite, CanSat, SAE/DBF or RC aircraft team, or a thesis in structures or mechanisms.
• Exposure to recovery systems, release devices, or pyrotechnic and safety‑critical mechanisms.
• Knowledge of multibody dynamics tools (Adams, MotionSolve, Simscape Multibody) or explicit FEA (LS-DYNA, Abaqus Explicit).
• Exposure to composite fabrication, tooling or NDT methods.
• Scripting in Python or MATLAB, and test experience with strain gauges, load cells and DAQ.

What you will gain

• Ownership of real flight hardware within months of joining.
• Exposure to the full UAV lifecycle, including launch and recovery.

Green Aero Propulsion is an equal opportunity employer and does not discriminate on the basis of race, color, religion, gender, sexual orientation, national origin, disability, age, or any other status protected by law. We're committed to a workplace where everyone is valued and respected. All hiring decisions are made on merit, qualifications, and business needs.