Senior UAV Design Engineer (UAV Systems)

Job Summary:

We are seeking a highly skilled Senior UAV Design Engineer to lead the end-to-end

mechanical development of next-generation Unmanned Aerial Vehicles. You will be responsible

for conceptualizing, designing, and validating complex airframe structures and internal systems.

The ideal candidate possesses deep expertise in CATIA, advanced structural analysis (FEA),

and Computational Fluid Dynamics (CFD), alongside a robust understanding of material science

(metals and composites) and aerospace documentation standards.

Key Responsibilities:

1. Advanced CAD Design & Modeling

● Lead the design of UAV airframes, enclosures, and internal component layouts using

CATIA 3DEXPERIENCE.

● Concept to product designer for high-fidelity 3D models and detailed 2D manufacturing

drawings using GD&T (Geometric Dimensioning and Tolerancing) to ensure precision

and assembly compatibility.

● Optimize designs for weight, aerodynamics, and ease of assembly (DFM/DFA).

2. Structural Analysis & Simulation

● Conduct complex Finite Element Analysis (FEA) for static, dynamic, vibration, and

fatigue loading to ensure structural integrity.

● Perform CFD analysis to optimize aerodynamic profiles, cooling systems, and

propulsion efficiency.

● Correlate simulation data with physical test results to refine and validate digital twins.

3. Materials Science & Component Selection

● Select and validate advanced materials (Carbon Fiber Composites, Aerospace-grade

Alloys, high-performance polymers) based on strength-to-weight ratios and

environmental durability.

● Oversee the integration of critical UAV components, including propulsion systems

(BLDC motors, ESCs), flight controllers, sensors (LiDAR, Gimbal, GPS), and battery

management systems.

4. Validation & Testing

● Develop and execute Design Verification Plans & Reports (DVP&R).

● Oversee structural testing (drop tests, stress tests, environmental chambers) and flight

testing phases to validate design requirements.

● Utilize DFMEA (Design Failure Mode and Effects Analysis) to identify and mitigate

potential risks early in the development cycle.

5. Documentation & Regulatory Standards

● Ensure all designs comply with international standards such as ASTM F38, MIL-STD-

810H, or local certifications (e.g., DGCA/EASA/FAA).

● Maintain rigorous documentation including Bill of Materials (BOM), Technical Data

Packages (TDP), and Unmanned Aircraft Flight Manuals (UFM).

Required Skills & Qualifications:

● Education: B.Tech/M.Tech in Aerospace, Aeronautical, or Mechanical Engineering.

● Experience: 5–8+ years in UAV or Aerospace design, with at least 3 years in a senior or

lead capacity.

● Software Proficiency:

○ Expert: CATIA (Part Design, Generative Shape Design, Assembly).

○ Simulation: ANSYS (Fluent/Mechanical), Abaqus, or Nastran/Patran.

○ Analysis: MATLAB/Simulink for flight dynamics.

● Technical Knowledge: Deep understanding of composite manufacturing (hand layup,

vacuum bagging) and rapid prototyping (3D printing).

● Soft Skills: Strong leadership, ability to mentor junior engineers, and excellent cross-

functional communication skills.

Preferred Qualifications:

● Experience with design assurance levels.

● Hands-on experience in flying UAVs (Pilot certification is a plus).

● Knowledge of hybrid-electric propulsion systems.