Engineer I Aerostructures & FEA

As an Engineer-I Aerostructures & FEA at ideaForge, you will play a crucial role in the R&D Mechanical team by combining aerostructure design with simulation-driven structural analysis to develop UAV airframes that are lightweight, robust, and ready for certification. Your technical rigor, collaboration skills, and eagerness to grow will be essential in conducting various tasks including aerostructure design, tooling & assembly definition, PLM integration, FEA analysis, material engineering, 3D printing, cross-functional support, and root cause analysis. Key Responsibilities: - Design and develop composite and metallic aerostructures such as wings, fuselage, empennage, etc., using a first principal approach. - Perform aerosizing and structural sizing calculations for lightweight optimization. - Create CAD models and engineering drawings following DFMA principles. - Design composite parts, analyze layup feasibility, and optimize for weight reduction. - Evaluate and select composite materials and manufacturing processes. - Proficiency in TAD principles, tooling, and assembly strategies. - Prepare assembly BOMs, jigs, fixture interfaces, and support design-to-assembly planning. - Experienced in Product Lifecycle Management (PLM) systems. - Conduct FEA analysis for structural strength, vibration, and stability evaluation. - Evaluate designs for manufacturability, cost efficiency, and reliability. - Knowledge of additive manufacturing techniques and material properties. - Provide technical support, participate in flight trials, and contribute to CAE methodologies. - Capable of root cause analysis in collaboration with CFT. Qualifications Required: - Bachelors or masters degree in mechanical engineering, Aerospace Engineering, or related discipline. - 3-5 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). - 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. At ideaForge, you will be part of a pioneering company in the industrial and surveillance UAV manufacturing sector in India. With a focus on indigenous technology and innovation, you will contribute to products that have consistently supported Indian Defence, Paramilitary, and Police forces in ensuring citizen safety and saving lives. Join us in our mission to make a difference and drive technological advancements in the UAV industry. As an Engineer-I Aerostructures & FEA at ideaForge, you will play a crucial role in the R&D Mechanical team by combining aerostructure design with simulation-driven structural analysis to develop UAV airframes that are lightweight, robust, and ready for certification. Your technical rigor, collaboration skills, and eagerness to grow will be essential in conducting various tasks including aerostructure design, tooling & assembly definition, PLM integration, FEA analysis, material engineering, 3D printing, cross-functional support, and root cause analysis. Key Responsibilities: - Design and develop composite and metallic aerostructures such as wings, fuselage, empennage, etc., using a first principal approach. - Perform aerosizing and structural sizing calculations for lightweight optimization. - Create CAD models and engineering drawings following DFMA principles. - Design composite parts, analyze layup feasibility, and optimize for weight reduction. - Evaluate and select composite materials and manufacturing processes. - Proficiency in TAD principles, tooling, and assembly strategies. - Prepare assembly BOMs, jigs, fixture interfaces, and support design-to-assembly planning. - Experienced in Product Lifecycle Management (PLM) systems. - Conduct FEA analysis for structural strength, vibration, and stability evaluation. - Evaluate designs for manufacturability, cost efficiency, and reliability. - Knowledge of additive manufacturing techniques and material properties. - Provide technical support, participate in flight trials, and contribute to CAE methodologies. - Capable of root cause analysis in collaboration with CFT. Qualifications Required: - Bachelors or masters degree in mechanical engineering, Aerospace Engineering, or related discipline. - 3-5 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). - Knowledge of DFX, DFM, and high-performance material-process pairing. - Hands-on experience with 3D printing tools and decision-making for rapid prototyping