UAV Design Engineer – Aerodynamics & CFD

Skylark Group; Gurugram District; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

Skylark Group in Gurugram, Haryana is seeking a hands-on Design Engineer to drive the design, development, testing, and optimization of next‑generation drone and UAV systems.

The ideal candidate is a practical, field-tested engineer with strong expertise in mechanical design, UAV structures, aerodynamics, CFD, materials, and manufacturing—someone who has independently taken UAV components or complete systems from concept through CAD, analysis, prototyping, manufacturing, testing, and real-world

Qualifications

• Education: Bachelor's or Master's in Aerospace, Aeronautical, Mechanical, or related field.
• Proven independent ownership of UAV/drone mechanical and structural designs.
• Demonstrable experience with UAV components or systems manufactured, tested, and deployed in the field.
• Strong grounding in aerodynamics, fluid mechanics, and UAV structural design.
• Proficiency in CAD tools: SolidWorks, Fusion 360, AutoCAD or equivalent.
• Hands-on CFD analysis using ANSYS Fluent/CFX.
• Knowledge of composite materials, lightweight structures, CNC, and additive manufacturing.
• Strong analytical and troubleshooting skills.

Responsibilities

• Independently design UAV airframes, structural components, and mechanical sub-assemblies.
• Develop production-ready 3D models and 2D drawings (SolidWorks, Fusion 360, AutoCAD).
• Own designs end-to-end—from concept through prototyping, manufacturing, and field deployment.
• Balance weight, strength, stability, durability, and manufacturability in every design decision.
• Collaborate with electronics, flight-control, and systems teams on integration and weight distribution.
• Reverse engineering to scan a model and modify as required.
• Apply practical aerodynamics knowledge to real UAV flight scenarios.
• Run CFD simulations to optimize lift, drag, stability, and efficiency.
• Translate simulation results into concrete design changes.
• Diagnose and resolve aerodynamic issues observed during flight tests.
• Select materials based on strength, weight, cost, and durability.
• Apply design-for-manufacturing principles to keep production-readiness.
• Coordinate with fabrication teams on CNC, 3D printing, and composite molding.
• Validate designs through prototyping, ground testing, and flight testing.
• Use field feedback and test data to drive design iteration.
• Produce detailed drawings, specs, and BOMs.
• Ensure designs meet engineering, safety, and regulatory standards.
• Maintain configuration control throughout lifecycle.
• Collaborate with flight-control, electronics, manufacturing, and operations teams.

Skills

UAV design ownership

CAD proficiency

CFD analysis

Aerospace background

Troubleshooting

Education

Bachelor's or Master's in Aerospace/Mechanical

Related engineering field

Tools

SolidWorks

Fusion 360

AutoCAD

ANSYS Fluent/CFX

Job description

Experience: 4-6 years

Role Overview

We are looking for a hands‑on Design Engineer to join our core engineering team and drive the design, development, testing, and optimization of next‑generation drone and UAV systems.

The ideal candidate is a practical, field-tested engineer with strong expertise in mechanical design, UAV structures, aerodynamics, CFD, materials, and manufacturing - someone who has independently taken UAV components or complete systems from concept through CAD, analysis, prototyping, manufacturing, testing, and real-world field deployment, not just theoretical or simulation work.

Key Responsibilities

UAV & Mechanical Design

• Independently design UAV/drone airframes, structural components, and mechanical sub-assemblies.
• Develop production-ready 3D models and 2D engineering drawings (SolidWorks, Fusion 360, AutoCAD, or equivalent).
• Own designs end-to-end — from concept through prototyping, manufacturing, and field deployment.
• Balance weight, strength, stability, durability, and manufacturability in every design decision.
• Partner with electronics, flight‑control, and systems teams on integration and weight distribution.
• Reverse engineering capabilities to scan a model and prepare the design with required modification.

Aerodynamics & CFD

• Apply practical aerodynamics and fluid mechanics knowledge to real UAV flight scenarios.
• Run CFD simulations (ANSYS Fluent/CFX or equivalent) to optimize lift, drag, stability, and efficiency.
• Translate simulation results into concrete design changes.
• Diagnose and resolve aerodynamic issues that surface during actual flight testing, not just on paper.

Manufacturing & Materials

• Select materials (carbon‑fiber composites, high‑strength polymers, lightweight alloys, aerospace‑grade materials) based on strength, weight, cost, and durability requirements.
• Apply design‑for‑manufacturing (DFM) principles to keep designs production‑ready and repeatable.
• Coordinate with fabrication teams on CNC machining, 3D printing, and composite molding.

Testing & Field Validation

• Validate designs through prototyping, ground testing, and flight testing.
• Use field feedback and test data to drive continuous design iteration.
• Demonstrate a track record of designs that are personally developed and currently operating in the field - not shelved prototypes.

Documentation & Compliance

• Produce detailed engineering drawings, specifications, and BOMs.
• Ensure designs meet applicable engineering, safety, and regulatory standards.
• Maintain configuration control and documentation throughout the product lifecycle.

Cross‑Functional Collaboration

• Work closely with flight‑control, electronics, manufacturing, and operations teams to resolve design and performance issues.
• Support fast design iteration cycles based on test data and operational needs.

Required Qualifications & Skills

• Education Bachelor's or Master's degree in Aerospace, Aeronautical, Mechanical, or Mechanical Design Engineering, or a related field.
• Proven, independent ownership of UAV/drone mechanical and structural designs — not just design support.
• Demonstrable experience with UAV components or systems that have been manufactured, tested, and deployed in the field.
• Strong practical grounding in aerodynamics, fluid mechanics, and UAV structural design.
• Proficiency in SolidWorks, Fusion 360, AutoCAD, or equivalent CAD tools.
• Hands‑on CFD analysis experience using ANSYS Fluent/CFX or equivalent.
• Working knowledge of composite materials, lightweight structures, CNC machining, and additive manufacturing.
• Strong analytical and troubleshooting skills, with the ability to turn theory into flight ready hardware.

Preferred

• FEA/structural and multi‑physics simulation experience.
• Experience with fixed‑wing UAVs, multirotors, VTOL, or other autonomous aircraft.
• Direct experience working with manufacturing/fabrication teams and running flight tests.
• Background in aerospace, defence, aviation, drone, or robotics industries.
• Strong technical communication skills.

Ideal Candidate

Someone who can point to a real design lifecycle they've owned: Design → Analysis → Manufacturing → Testing → Field Deployment.