Senior Electromechanical Engineer

Ubifly Technologies; Chennai District; On-site; INR 900,000 - 1,300,000; Full time

Job summary

Ubifly Technologies seeks a Senior Electromechanical Engineer to own the packaging, housing, and mechanical integration of high-voltage battery modules and eVTOL powertrain components into the airframe. You will bridge electrical power architectures with structural mechanics to optimize weight, thermal paths, and flight readiness.

You will collaborate across electrical and mechanical teams to drive DfM/DFx, ensure GD&T compliance, and deliver robust, manufacturable enclosures and assemblies for

Qualifications

• 6–9 years in mechanical or electromechanical packaging in aerospace/EV/high-reliability sectors.
• CAD mastery in CATIA V5/V6 (3DEXPERIENCE) for complex assemblies and sheet metal.
• Expert GD&T with tolerance stack-ups and ASME Y14.5 compliance.
• Experience designing parts for CNC, sheet metal, bonding, casting/molding.
• Knowledge of electrical constraints: ingress, IP, clearance, creepage, panels.
• Prototype to production workflows; full certification in aviation/defense domains.

Responsibilities

• Enclosure & packaging design for high-voltage packs and power electronics.
• Advanced 3D modeling to optimize aerodynamic integration and routing.
• Perform GD&T and tolerance stack-up analyses for fitment accuracy.
• Implement DfM/DfA/DfT principles to reduce part counts and assembly time.
• Select aerospace-grade materials and TIMs for heat dissipation and safety.
• Coordinate HV isolation and creepage/clearance with electrical teams.
• Design for certification and production planning environments.

Skills

Aerospace packaging experience

CATIA V5/V6 (3DEXPERIENCE)

GD&T (ASME Y14.5)

DFM/DFx/DFT

CNC machining experience

Electrical system design awareness

Certification / compliance mindset

Tools

CATIA tooling and workflows

Job description

As a Senior Electromechanical Engineer, you will own the physical packaging, structural housing, and mechanical integration of our high-voltage battery modules and electrical powertrain systems into the eVTOL airframe. This is a highly cross-functional role bridging electrical power architectures and structural mechanics. You will transform complex electrical systems into flight-ready, structural assemblies, ensuring optimal thermal paths, structural integrity under high-g flight envelopes, and strict optimization for aircraft weight and mass balance.

What You Will Do

• Enclosure & Packaging Design: Design robust, lightweight, and crash-worthy enclosures, mounts, and structural brackets for high-voltage battery packs, power electronics, power distribution units (PDUs), and inverter modules.
• Advanced 3D Modeling: Utilize CATIA V5/V6 (3DEXPERIENCE) to build complex electromechanical assemblies, leveraging surface modeling for aerodynamic integration and airframe routing constraints.
• Precision Engineering & GD&T: Apply rigorous Geometric Dimensioning & Tolerancing (GD&T) principles per ASME Y14.5 to ensure flawless fitments between machined enclosures, sheet metal shields, and composite airframe interfaces. Perform detailed tolerance stack-up analyses.
• Design for Excellence (DfM / DfA / DfT): Inject Design for Manufacturing, Assembly, and Testing principles early into the development lifecycle to drive down component counts, minimize assembly cycle times, and simplify shop-floor production.
• Material & Structural Selection: Select and qualify aerospace-grade alloys, high-performance plastics, structural adhesives, and advanced Thermal Interface Materials (TIMs) to maximize heat dissipation while ensuring structural safety.
• HV Isolation Engineering: Coordinate closely with the electrical team to design mechanical clearances that respect strict creepage and clearance boundaries for high-voltage components.
• HV Box Design: Assemblies involving Contactors, Busbars, Fuses, Pyrofuses, Manual Service Disconnect switches, etc.

What We Are Looking For (Must-Haves)

• Experience : 6 to 9 years of dedicated mechanical or electromechanical packaging experience within the aerospace, electric vehicle (powertrain/battery), or high-reliability defense sectors.
• CAD Mastery : Advanced, hands-on expertise in CATIA V5 / V6 (3DEXPERIENCE) , specifically utilizing advanced assembly design, sheet metal workbenches, and mechanical part design.
• Drafting & Stack-up Depth : Expert-level knowledge of GD&T and a proven track record of resolving complex multi-part tolerance stack-ups.
• Manufacturing Knowledge : Direct experience designing parts optimized for CNC machining, sheet metal fabrication, structural bonding, and lightweight casting or molding.
• Exposure to Electrical System Design constraints : Excellent understanding & design capability on - Ingress protections, Water proof / Dust proof designs, Good understanding of clearance & creepage distances, Switches Panel creation, Electrical sub-assemblies.
• Certification / Compliance : Experience in prototyping as well as production planning kind of environment. Ideal candidates should have designed, developed & taken at least one such development through full certification through the likes of DGCA / CEMILAC / ARAI.

Preferred Skills (Good-to-Have)

• Working knowledge of Mechanical Shape Design within CATIA for complex surface modeling.
• Experience packaging high-voltage systems ( upto 800VDC ) and managing mechanical safety barriers against electric shock or thermal runaway.
• Familiarity with environmental testing standards like RTCA DO-160 (specifically regarding vibration, shock, and thermal profiles).
• Excellent understanding of electrical system design, electrical properties of materials, dielectric strength, creepage & clearances, thermal properties of materials.
• Good understanding of - Grounding / bonding required for electrical components, Enclosure design & fabrication for electrical systems, Design for Ingress Protections.
• Exposure to material selection for electrical products.