Senior Engineer - Mechanical Design (Composite)

ideaForge; Navi Mumbai; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

ideaForge is looking for a Senior Engineer – Mechanical Design in Navi Mumbai, Maharashtra. The successful candidate will lead the mechanical design of hybrid UAV systems, ensuring design excellence and manufacturability. Candidates should have a Bachelor’s or Master’s in Mechanical Engineering, with 8+ years of experience in related fields. Knowledge of composite materials and hands-on experience with CAD tools such as Creo is essential. This role involves cross-functional collaboration and commitment to project timelines.

Qualifications

• Eight or more years of experience in mechanical product design, preferably in aerospace, UAVs, or robotics.
• Proficiency in 3D CAD modeling, TAD, and GD&T.
• Knowledge of aerospace-grade composite material design is a must.

Responsibilities

• Lead mechanical design of hybrid UAV subsystems and payload interfaces.
• Evaluate designs for manufacturability, cost efficiency, and reliability using DFM and DFX.
• Work closely with systems engineering, integration, sourcing, testing, and manufacturing teams.

Skills

Mechanical Product Design

3D CAD Modeling (Creo)

Composite Material Engineering

Cross-Functional Collaboration

Education

Bachelor's or Master's in Mechanical Engineering

Tools

PTC Creo

Windchill PLM

Job description

ideaForge is the leader in industrial and surveillance UAV manufacturing in India with more than 50 percent market share. The organization was established in 2007 by IIT Bonnell alumni and is based out of Navi Mumbai, Maharashtra. ideaForge co‑designed India’s first Surveillance quadrotor UAV, NETRA, with the Defense Research & Development Organization and is also responsible for engineering the then world’s lightest Autopilot. It develops completely indigenous technology for Unmanned Aerial Systems and is a pioneer in the UAS segment in India, holding multiple IPs.

Position Overview

We are seeking a Senior Engineer – Mechanical Design to join our dynamic and interdisciplinary UAV engineering team. The candidate will be responsible for the mechanical design and development of hybrid UAV systems and subsystems, focusing on design excellence, manufacturability, integration readiness, and cross‑functional collaboration.

Job Description

• CAD‑Based Mechanical Design & Ownership
• Lead the mechanical design of hybrid UAV subsystems and payload interfaces using advanced parametric CAD tools (preferably PTC Creo).
• Develop and maintain complex CAD trees, system layouts, and 3D model integrity across revisions.
• Drive modular and scalable design practices in line with product architecture.
• Composite Material Engineering & Manufacturability
• Proficient in composite materials (Long Carbon, Aramid, Glass fiber), hand calculations, and manufacturing processes.
• Develop feasible design concepts and support the manufacturing team to achieve required performance during development.
• Strong knowledge of materials (metals, polymers, composites) with clear understanding of process‑specific constraints.
• Evaluate designs for manufacturability, cost efficiency, and reliability using DFM, DFX, and material selection tools.
• Prior experience with high‑performance materials, injection molding, and machining processes is advantageous.
• TAD (Tooling & Assembly Definition)
• Proficient in TAD principles with hands‑on experience in tooling and assembly strategies.
• Prepare assembly BOMs, jigs and fixture interfaces, and support design‑to‑assembly planning.
• Contribute to design improvements based on ease of assembly, maintainability, and ergonomics.
• PLM Integration
• Experienced in Product Lifecycle Management systems for version control, workflows, and digital thread management.
• Familiar with Windchill PLM or equivalent for part structures, release cycles, and change management.
• Structural Design & Collaboration
• Sound understanding of structural analysis fundamentals (loads, boundary conditions, safety factors, fastener design).
• Interpret FEA results, collaborate with analysis teams, and optimize design based on structural feedback.
• Additive Manufacturing & 3D Printing
• Well‑versed in 3D printing techniques (FDM, SLA, SLS, MJF, DMLS).
• Select suitable printer types, grain structures, material properties, and post‑processing requirements based on use‑case.
• Cross‑Functional Collaboration
• Work closely with systems engineering, integration, sourcing, testing, and manufacturing teams.
• Take ownership of delivery, resolve cross‑domain design issues, and ensure on‑time maturity of the mechanical stack.
• Support V&V (Validation and Verification) activities and ensure compliance with technical specs and regulatory needs.
• Root Cause Analysis
• Understand physical behavior, correlate with design definition, and derive root causes in collaboration with CFT.

Skills & Qualifications

• Bachelor’s or master’s degree in mechanical engineering, aerospace engineering, or a related discipline.
• Eight or more years of experience in mechanical product design, preferably in aerospace, UAVs, or robotics.
• Proficiency in 3D CAD modeling (preferably Creo), TAD, and GD&T.
• Knowledge of aerospace‑grade composite material design is a must.
• Experience in PLM or PDM platforms, ideally Windchill.
• Exposure to FEA result interpretation and collaborative optimization with analysts.
• Knowledge of DFX, DFM, and high‑performance material–process pairing.
• Hands‑on experience with 3D printing tools and decision‑making for rapid prototyping vs. end‑use applications.
• Strong documentation and presentation skills.

Desired Behaviours

• Commitment to common purpose and goals
• Respectfulness and collaborative spirit
• Integrity and ethics
• Initiative and ownership with accountability
• Passion for making a difference
• Maintaining harmonious interpersonal relationships