Generative Design & Additive Mfg Lead

AlgoForge Aerospace; Bengaluru; On-site; INR 3,000,000 - 5,400,000; Full time

Job summary

AlgoForge Aerospace in Bengaluru, India seeks a Generative Design & Additive Manufacturing Lead to push the boundaries of topology optimization and DMAM. You will drive end-to-end optimization for airframe structures, engine mounts and turbomachinery housings, with a focus on reducing part counts and enhancing performance.

You will manage a fleet of LPBF/DED machines and collaborate with Propulsion and Fluid Systems teams to embed complex cooling channels directly into structural walls,

Qualifications

• BS/MS in Mechanical Engineering, Aerospace Engineering, or Computational Geometry.
• Expert-level proficiency in generative design platforms (e.g., nTopology, Altair Inspire, Siemens NX Advanced).
• Hands-on experience with industrial metal additive manufacturing machines (EOS, SLM, Velo3D).
• Strong structural intuition and mastery of FEA to validate algorithmic meshes.

Responsibilities

• Lead end-to-end topology optimization of airframe structures, engine mounts, and turbomachinery housings.
• Implement aggressive DfAM principles to minimize supports and optimize print orientation.
• Run complex structural and thermal FEA to validate geometries under dynamic and thermal loads.
• Manage LPBF/DED printer fleet to realize designs.
• Collaborate with propulsion and fluid systems teams to embed internal cooling channels in walls.

Skills

Topology optimization

Generative design

FEA

Thermal analysis

Collaboration

Education

BS/MS in Mechanical Engineering

Aerospace Engineering

Computational Geometry

Tools

nTopology

Altair Inspire

Siemens NX Advanced

EOS

SLM

Velo3D

Job description

Mission Overview

At AlgoForge Aerospace, excess mass is a mission failure. As the Generative Design & Additive Manufacturing Lead, you will discard centuries of traditional machining constraints and embrace algorithmic geometry.

You will utilize advanced topology optimization to grow organic, hyper-efficient structural components and complex fluid manifolds. By leveraging massive-scale metal 3D printing (LPBF/DED), your goal is to reduce engine part counts from thousands down to single, monolithic pieces of flight hardware.

Operational Objectives

• Drive the end-to-end topology optimization of primary airframe structures, engine mounts, and complex turbomachinery housings.


• Implement highly aggressive Design for Additive Manufacturing (DfAM) principles to eliminate support structures and optimize print orientations.


• Run complex structural and thermal FEA simulations to validate generative geometries against max dynamic pressure and thermal shock.


• Manage the fleet of massive-format Laser Powder Bed Fusion (LPBF) and Directed Energy Deposition (DED) machines to physically realize your designs.


• Collaborate relentlessly with the Propulsion and Fluid Systems teams to integrate complex internal cooling channels directly into structural walls.

Mission Prerequisites

• BS/MS in Mechanical Engineering, Aerospace Engineering, or Computational Geometry.


• Expert-level proficiency in advanced generative design platforms (e.g., nTopology, Altair Inspire, Siemens NX Advanced).


• Deep, hands-on experience running industrial metal additive manufacturing machines (EOS, SLM, Velo3D).


• Strong structural intuition and mastery of Finite Element Analysis (FEA) to validate algorithmically generated meshes.


• A visceral hatred for unnecessary fasteners, flanges, and excess mass.

Deployment Benefits

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  Unlimited Compute

  
  

  Harness massive cloud clusters to run multi-variable topology optimizations.

  
  


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  Part Reduction

  
  

  Consolidate 100-part assemblies into a single, seamless print.

  
  


• 
  

  Printer Fleet

  
  

  Direct control over top-tier industrial metal 3D printers.

  
  


• 
  

  Zero Legacy

  
  

  We don't do things 'the old way'. If an algorithm designs it better, we print it.