Aerospace & Defense Senior Design Engineer

Tata Consultancy Services; Troy (MI); On-site; USD 100,000 - 130,000; Full time

Benefits offered by this job

Discretionary Annual Incentive

Comprehensive Medical Coverage

Dental & Vision Coverage

401K Plan

Training & Certification Reimbursement

Job summary

Tata Consultancy Services in Troy, MI is seeking an experienced aerospace design engineer to lead reverse-engineering efforts and redefine parts for manufacturability and qualification. You will manage EBOM/MBOM flows, create and update 3D models and drawings, and coordinate with ENG/ME/QE for signature releases.

The role requires 12-15+ years in aerospace design, strong CAD/PLM skills, DFMEA, and direct client interaction. Relocation assistance and benefits may be available.

Qualifications

• Bachelor's or Master's degree in Aerospace, Mechanical, or Manufacturing Engineering.
• 12-15+ years of aerospace product / design engineering experience, including reverse-engineering of legacy parts.
• Expert in 3D CAD and 2D drafting with GD&T.
• Hands-on EBOM/MBOM management in PLM / configuration-management system.
• DFMEA, tolerance stack-up, and Key Characteristics definition on production hardware.
• Aerospace qualification and part-release workflows experience.
• Strong stakeholder communication and client-facing reviews.

Responsibilities

• Lead reverse-engineering and redefine parts, manage EBOM-to-MBOM flow, and present manufacturable solutions for sign-off.
• Act as engineering point of contact for customer focal point.
• Lead data capture via 2D drawings, 3D CAD, and 3D scanning; specify scanner type and reconcile data.
• Perform Design for Manufacturing (DFM) and propose new-material opportunities.
• Create/update 3D models and 2D drawings to production standards.
• Create and manage EBOM/MBOM in the customer Configuration Manager.
• Conduct DFMEA and tolerance analysis to validate fit and robustness.
• Identify all Key Characteristics and CTIs.
• Manage qualification plan updates and signature-release MBOM.
• Provide technical direction to Manufacturing Engineer.

Skills

Aerospace engineering

Experience 12-15+ years

3D CAD

GD&T

EBOM/MBOM PLM

DFMEA

3D scanning

MBSE familiarity

Client communication

Education

Bachelor's or Master's in Aerospace/Mechanical/Manufacturing

BACHELOR OF COMPUTER SCIENCE

Tools

SOLIDWORKS

ALTIUM

CATIA

Creo

NX

GD&T tools

PLM/Configuration Manager

DFMEA tools

3D-scanning software

Job description

Must Have Technical/Functional Skills

• Bachelor's or Master's degree in Aerospace, Mechanical, or Manufacturing Engineering.
• 12-15+ years of aerospace product / design engineering experience, including reverse-engineering of legacy parts.
• Expert in 3D CAD and 2D drafting (e.g., SOLIWORKS, ALTIUM, CATIA or Creo) with the proven ability to author and update detail and assembly drawings to GD&T.
• Hands-on experience with EBOM/MBOM management inside a PLM / configuration-management system.
• Demonstrated DFMEA, tolerance stack-up, and Key Characteristic definition on production hardware.
• Working experience of aerospace qualification and part-release / signature workflows.
• Strong stakeholder communication; able to interface directly with client focal points and lead technical reviews.
• Tools & Software experience : 3D CAD & 2D drafting (SOLIDWORKS / ALTIUM / CATIA / Creo / NX /), GD&T, PLM / Configuration Manager for EBOM–MBOM, DFMEA & tolerance-analysis tools, 3D-scanning / reverse-engineering software.
• Hands-on experience specifying and integrating 3D-scanning / reverse-engineering workflows.
• Familiarity with UAV / unmanned-systems programs.
• Exposure to AS9100 / aerospace quality systems and DFM-driven cost reduction.
• Exposure to Model Based System Engineering (MBSE) a plus.

Roles & Responsibilities

• Lead reverse-engineering and re-definition of the part, drives the EBOM-to-MBOM flow inside the customer Configuration Manager, and is responsible for presenting to the customer solutions for a design that is manufacturable, qualifiable, and released through the ENG/ME/QE signature loop. The role is hands-on: following customer approval of the solutions, the engineer personally creates and updates 3D models and 2D detail and assembly drawings.
• Act as the engineering point of contact for the customer engineering focal point.
• Lead data capture of the existing part through 2D drawings, 3D CAD, and 3D scanning; specify the scanner type and reconcile scan data against customer specifications.
• Perform Design for Manufacturing (DFM): propose alternative designs and new-material opportunities and secure customer Engineering approval.
• Create and update 3D models and 2D drawings - part detail and assembly - to production standard (mandatory drawing-update capability).
• Create new part numbers and revise existing part numbers in collaboration with the designated customer employee, following configuration-management discipline.
• Create and manage the Engineering Bill of Materials (EBOM) in the customer Configuration Manager.
• Conduct Design FMEA (DFMEA) and tolerance stack-up analysis to validate fit, function, and robustness.
• Identify and explicitly list all Key Characteristics (KCs) and Critical-to-Inspection items (CTIs).
• Assess the qualification gap and propose updates to the qualification plan. Create / update the Qualification plan when proposed solutions are approved.
• Create the Manufacturing Bill of Materials (MBOM) and manage the signature release loop across ENG, ME, and QE.
• Provide technical direction to the Manufacturing Engineer

Generic Managerial Skills, If any

• Proven engineering project background
• Dealing with Engineering stakeholders of an organization
• Exposure in working with teams based in different geo and different time zones
• Ability to work both as "lone warrior" as well as "as a team player"

Base Salary Range : $100,000 to $130,000 Per Annum

TCS Employee Benefits Summary

• Discretionary Annual Incentive.
• Comprehensive Medical Coverage: Medical & Health, Dental & Vision, Disability Planning & Insurance, Pet Insurance Plans.
• Family Support: Maternal & Parental Leaves.
• Insurance Options: Auto & Home Insurance, Identity Theft Protection.
• Convenience & Professional Growth: Commuter Benefits & Certification & Training Reimbursement.
• Time Off: Vacation, Time Off, Sick Leave & Holidays.
• Legal & Financial Assistance: Legal Assistance, 401K Plan, Performance Bonus, College Fund, Student Loan Refinancing.

Qualifications

BACHELOR OF COMPUTER SCIENCE