Lead Engineer (UAV/Drone)

Designation: Technical Leader/Associate Technical Leader

Roles and Responsibilities:

• Lead the design, development, integration, and validation of electro-mechanical systems and components for UAV/Drone applications.
• Drive complete product development activities from concept definition through detailed design, prototype development, testing, validation, and production implementation.
• Design and develop UAV electro-mechanical systems and assemblies, including propulsion and actuation-related mechanisms.
• Develop and integrate components such as BLDC motor mounts, ESC interfaces, actuators, gimbal mechanisms, landing gear systems, payload deployment/release mechanisms, hinges, latches, locking mechanisms, thermal management components, and structural/electrical interfaces.
• Translate system-level requirements into subsystem and component-level requirements.
• Generate, evaluate, and optimize multiple design concepts based on performance, manufacturability, weight, and cost targets.
• Perform engineering calculations including force, torque, sizing, feasibility assessments, and tolerance stack-up analysis.
• Develop detailed 3D CAD models, assemblies, manufacturing drawings, and engineering documentation.
• Conduct design reviews and ensure compliance with GD&T and engineering standards.
• Support prototype development, design iterations, troubleshooting, and product maturation activities.
• Integrate mechanical, electrical, and electronic systems into the overall UAV architecture.
• Resolve packaging, accessibility, serviceability, and interface-related issues within the UAV platform.
• Coordinate closely with electrical, avionics, controls, software, aerodynamics, and manufacturing teams.
• Define and support component and subsystem validation plans.
• Participate in ground testing, flight testing, troubleshooting, and root-cause analysis activities.
• Analyze test results, correlate with engineering predictions and simulation data, and implement corrective actions.
• Support design verification and product validation activities throughout the development lifecycle.
• Provide technical guidance and mentorship to engineering teams and contribute to engineering best practices.

Skills and Experience Required:

• Qualification: BE / B.Tech / ME / M.Tech in Mechanical Engineering, Mechatronics, Electromechanical Engineering, Aerospace Engineering, or related discipline.
• Experience: 10–15 years of relevant experience in UAV, Drone, Aerospace, or related high-performance engineering product development.
• Proven experience developing UAV/Drone products from concept stage through prototype development, testing, validation, and production implementation.
• Strong understanding of the complete product development lifecycle including requirements management, concept development, architecture, detailed design, CAE, prototyping, testing, validation, manufacturing, and productionization.
• Strong fundamentals in mechanical design, machine design, mechanisms and kinematics, strength of materials, material selection, and manufacturing processes.
• Experience in designing assemblies involving bearings, shafts, gears, fasteners, sheet metal, machined components, composite materials, lightweight structures, and plastic components.
• Strong knowledge of electro-mechanical integration and UAV system architecture.
• Proficiency in CATIA, Creo, SolidWorks, NX, or equivalent CAD software.
• Strong understanding of GD&T, engineering drawings, tolerance stack-up analysis, and design review processes.
• Experience in UAV propulsion systems, payload integration, flight-control actuation systems, and electro-mechanical assemblies.
• Ability to perform or guide structural strength, stiffness, vibration, modal, shock, fatigue, durability, thermal, CFD, mechanism, and weight optimization studies.
• Experience with CAE tools such as ANSYS, Abaqus, LS-DYNA, Nastran, HyperWorks, OptiStruct, or equivalent is desirable.
• Knowledge of DFM, DFA, DFMEA, DFS, design optimization, supplier development, and PLM processes.
• Hands-on experience with Multirotor UAVs, Fixed-Wing UAVs, VTOL/eVTOL platforms, Autonomous Drones, Defense UAVs, Surveillance UAVs, Cargo Drones, Aerospace Mechanisms, and Payload Integration will be an added advantage.
• Strong analytical and problem-solving abilities with sound engineering judgment.
• Excellent communication, technical presentation, stakeholder management, and cross-functional collaboration skills.
• Strong ownership, accountability, and ability to drive engineering activities independently in a fast-paced product development environment.