Engineer – Structural Analysis (FEA) – MTS-I

COMRADO Aerospace; Bengaluru; On-site; INR 450,000 - 750,000; Full time

Job summary

COMRADO Aerospace in Bengaluru seeks a Structural Analysis (FEA) Engineer – Fresher to support UAV airframe design, finite element analysis, and structural qualification using ANSYS under supervision.

This entry-level position provides hands-on exposure to metallic and composite structures, loads, and validation workflows, with training and growth in aerospace structures, testing coordination, and technical documentation.

Qualifications

• Bachelor’s or Master’s degree in Aerospace or Mechanical Engineering.
• Fresher with 0–1 year experience or academic project in aircraft structures preferred.
• Strong fundamentals in structural analysis and materials.

Responsibilities

• Assist in defining structural requirements and load cases for UAV airframes.
• Build and refine FEA models from CAD geometry, including meshing and boundary conditions.
• Perform linear static, buckling, and modal analyses under guidance.
• Document results and support testing coordination and QA activities.

Skills

FEA

ANSYS

Aerospace structures

CAD basics

Python

Education

Bachelor’s or Master’s degree in Aerospace Engineering or Mechanical Engineering

Tools

ANSYS

Abaqus

MSC Nastran

HyperMesh

Femap

MATLAB

Python

Job description

Full time job/on site Urgent

We are looking for a Structural Analysis (FEA) Engineer – Fresher to support UAV airframe structural design, finite element analysis, and structural qualification activities. The role provides hands-on exposure to FEA, composite and metallic structures, structural testing, and aircraft structural analysis using tools such as ANSYS, under the guidance of senior engineers.

JOB CONTEXT / PURPOSE

Support the team responsible for airframe structural design, FEA, and structural qualification of UAVs primarily.

This is an entry-level role for a fresh graduate to build hands-on capability in aircraft structures, metallic/composite materials, structural analysis, and FEA using tools such as ANSYS, under the guidance of senior engineers.

KEY RESPONSIBILITIES

A. Functional / Team Responsibilities

• Assist in defining structural requirements, design constraints, and specifications based on project objectives and applicable airworthiness standards.
• Build and idealise finite element models of UAV airframe components and assemblies from CAD geometry, including geometry clean-up, element selection, meshing, joints, connections, contacts, and boundary conditions.
• Perform linear static, buckling, modal, fatigue, and thermal-structural analyses of primary and secondary airframe structures under senior guidance.
• Perform composite laminate definition and analysis, including ply lay-up, failure criteria, inter-laminar checks, and sandwich construction.
• Derive and apply load cases from flight, ground, landing, gust, and manoeuvre conditions; compute margins of safety for critical load cases.
• Validate FEA against classical hand calculations, analytical methods, and available test data; check mesh quality, convergence, and realistic load paths.
• Support structural sizing and weight optimisation through design iterations involving lay-up, thickness, material selection, and joint configuration.
• Support coupon, element, and component-level structural testing, including test article definition, instrumentation plans, and test matrices.
• Support code and SOP development for structural analysis/FEA workflows.
• Stay updated with UAV advancements, emerging technologies, and industry trends through research and continuous learning.

B. Technical Documentation

Prepare high-quality technical documentation for design, analysis, and testing, including:

• Structural design/stress analysis reports with load cases, assumptions, and margins of safety.
• Test matrices and reports.
• Detailed diagrams.
• Material selection and laminate definition/lay-up documents.
• Model documentation covering idealisations, assumptions, load cases, boundary conditions, and result summaries.

C. Additional Functions

• Coordinate with aerodynamics, propulsion, flight, and system engineering teams for inputs/outputs including loads, interfaces, mass budgets, and mounting provisions.
• Support manufacturing/quality teams on composite processing, defect disposition, and repair schemes.
• Support the flight team on structural clearances and post-flight inspection.

MANAGERIAL RESPONSIBILITIES

• Plan and track own tasks and deliverables against timelines; flag risks and delays early.
• Follow best practices, design standards, and QA processes.
• Maintain traceable records of analysis, inputs, assumptions, and results for team review.

KNOWLEDGE, SKILLS & EXPERIENCE

Educational Qualification

• Bachelor’s or Master’s degree in Aerospace Engineering, Mechanical Engineering, or a related field.
• Specialization in structures, mechanics of solids, and composite materials preferred.

Experience

• Fresher with 0–1 year of experience.
• Internship, academic project, or final-year thesis in aircraft structures, FEA, composite materials, or UAVs preferred.

TECHNICAL COMPETENCIES

UAV Systems

• Fixed-wing, VTOL, and multirotor UAVs.
• Major airframe assemblies including wing, fuselage, empennage, booms, and landing gear.
• Payload and propulsion integration.
• Understanding that system-level choices drive structural loads and interfaces.

Aircraft Structures

• Spars, ribs, stringers, skins, bulkheads, longerons, joints, and fittings.
• Load paths, shear flow, bending, torsion, buckling, and crippling.
• Strength of materials.
• Theory of elasticity.
• Structural dynamics and vibration.
• Basics of fatigue, damage tolerance, and fracture.

Aerospace Materials

• Aluminium alloys, steels, titanium, and polymer-matrix composites.
• Carbon/glass fibre, prepreg, sandwich cores, and adhesives.
• Mechanical properties, allowables, and material selection criteria.

Composite Mechanics

• Classical Lamination Theory.
• Ply orientation and lay-up.
• Maximum stress/strain criteria.
• Tsai-Hill and Tsai-Wu criteria.
• Delamination.
• 1D, 2D, and 3D element types/formulations.
• Meshing and mesh quality.
• Boundary conditions and constraints.
• Contacts.
• Result interpretation and sanity-checking.

FEA Tools

• Working knowledge of ANSYS Mechanical/Workbench and ACP for composites.
• Static, buckling, modal, and thermal-structural analysis.
• Exposure to Abaqus, MSC Nastran/Patran, HyperMesh, and Femap is an advantage.

Classical Analysis

• Classical hand calculations to size structures and independently verify FE results.

Manufacturing Awareness

• Composite lay-up and curing.
• Bonding and fastening.
• Sheet-metal forming.
• Machining.
• Additive manufacturing.

Programming / Automation

• Exposure to MATLAB, Python, and ANSYS APDL for automation and post-processing through coursework, projects, or internships.

BEHAVIORAL COMPETENCIES

• Excellent problem-solving and analytical thinking.
• Strong attention to detail and accuracy in structural calculations, analysis, and documentation.
• Effective communication and interpersonal skills.
• Ability to work with multidisciplinary teams.
• Willingness to learn, take direction, and act on feedback.
• Adaptability and flexibility in a fast-pace and evolving UAV environment.

SPECIFIC TOOL KNOWLEDGE

FEA

• ANSYS ACP.
• Abaqus, MSC Nastran/Patran, HyperMesh, and Femap as an advantage.
• Load cells.
• Accelerometers.
• DIC as an advantage.

CAD

• SolidWorks.
• CATIA.
• NX.
• Fusion 360 for geometry creation, clean-up, and defeaturing.

Other Tools

• MATLAB.
• Python.
• MS Excel.
• MS Word.

UAV-SPECIFIC COMPONENTS

Knowledge/exposure to:

• Electric propulsion units.
• Payload mounts.
• Fastening hardware.
• Other UAV-specific components.

INTERNAL CONTACTS

Multi-disciplinary Teams and Management
Purpose: Data and requirements exchange
Frequency: Regular

Testing Teams
Purpose: Help identify correct test standards and prepare test matrices
Frequency: Regular