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Engineer I Aerostructures & FEA

ideaForge -
Navi Mumbai, Maharashtra

Apply Now

Job details

Full-time
4 hours ago

Qualifications

Mechanical engineering
CAD
Mechanical Engineering
Aerospace Engineering
GD&T
Master's degree
Assembly
Project management
Bachelor's degree
ANSYS
FEA
Plastics injection moulding
Robotics
Mechanical knowledge
Creo
Product lifecycle management

Full job description

R&D - Mech

Navi Mumbai (On-Site)

Entry-level

1-3 years

Fulltime

Job Description

COMPANY PROFILE

ideaForge is the leader in industrial and surveillance UAV manufacturing in India with

more than 50% market share. Established in 2007 by IIT-Bombay alumni and

headquartered in Navi Mumbai, Maharashtra, ideaForge co-designed India''s first

surveillance quadrotor UAV — NETRA — with DRDO, and engineered the then world''s

lightest Autopilot. The company develops completely indigenous technology for

Unmanned Aerial Systems (UAS) and is a pioneer in the UAS segment with multiple

intellectual properties. ideaForge operates fully in-house R&D, design,

manufacturing, software, services, and training. Its products have consistently

helped Indian Defence, Paramilitary, and Police forces ensure citizen safety

and save lives.

POSITION OVERVIEW

We are seeking a passionate and driven Engineer-I – Aerostructures & FEA to join our R&D Mechanical team. This role combines hands-on aerostructure design with simulation-driven structural analysis (FEA) to develop lightweight, robust, and certification-ready UAV airframes. The ideal candidate is technically rigorous, collaborative, and eager to grow across composite design,

structural analysis, physical validation, and continuous improvement activities.

JOB DESCRIPTION

1. Aerostructure Design & Development

Design and develop composite and metallic aerostructures including wings, fuselage, empennage, landing legs, hinges, and gliders using first principal approach.

Perform aerosizing and structural sizing calculations for lightweight optimisation across UAV platforms.

Create CAD models and detailed engineering drawings adhering to DFMA principles.

Design composite parts and analyse layup feasibility; perform draping and structural optimisation for weight reduction.

Evaluate and select composite materials and manufacturing processes (hand lay-up, prepreg, RTM, etc.).

Apply Classical Laminate Theory (CLT) and ply optimisation to achieve required stiffness-to-weight targets.

2. TAD (Tooling & Assembly Definition)

Must be 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.

3. PLM Integration

Experienced in Product Lifecycle Management (PLM) systems for version control, workflows, and digital thread management.

Familiarity with Windchill PLM or equivalent for part structures, release cycles, and change management.

4. FEA – Structural Strength & Vibration analysis

Assist in static, non-linear, and buckling analysis under operational and extreme load cases.

Support composite modelling, laminate optimisation, and stability evaluation using ANSYS ACP or equivalent.

Validate structural safety margins and compliance under drop and operational loads.

Develop understanding of load case development, boundary conditions, and failure theories (aerospace structural standards).

Support vibration simulations including Modal, Harmonic, Frequency Response Function (FRF), and dynamic response analysis for UAV/eVTOL structures.

Identify natural frequencies, mode shapes, and critical excitation zones to reduce resonance risk.

5. Material Engineering & Manufacturability

Strong knowledge of materials (metals, polymers, composites) with a clear understanding of process-specific constraints.

Evaluate designs for manufacturability, cost efficiency, and reliability using DFM, DFX, and material selection tools.

Prior experience working with high-performance materials, injection molding, and machining processes is advantageous.

6. Additive Manufacturing & 3D Printing

Well-versed in 3D printing techniques (FDM, SLA, SLS, MJF, DMLS,etc.).

Ability to select suitable printer types, grain structures, material properties, and post-processing requirements based on the use-case.

7. Cross-Functional & Organisational Contribution

Provide technical support to Sales & Project Management teams.

Participate in flight trials and tech-driven swimlanes (propulsion, payload vibrations, aerostructure).

Support development of CAE methodologies, SOPs, material databases, and internal simulation tools.

8. Root Cause Analysis

Should be capable to 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.

1-3 years of experience in mechanical product design, preferably in aerospace, UAVs, or robotics.

Proficiency in 3D CAD modeling (preferably Creo), TAD, and GD&T.

Experience in PLM/PDM platforms, ideally Windchill.

Familiarity with FEA tools (ANSYS Mechanical / ANSYS ACP or equivalent); exposure to static, modal analysis

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 BEHAVIOURAL VALUES:

Commitment to common purpose and goals.

Seating respect on the table.

Displaying Integrity and Ethics.

Taking Initiative and ownership with Accountabilities.

Being Passionate about making a difference.

Maintaining and managing interpersonal harmonious relationships.

Skills

Creo Parametric

GD&T

Finite Element Analysis

Design

CAD

ANSYS

Report Generation

Composites

Material Selection

RCA

Testing

Machine Design

Apply Now

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