Engineer II -Aerostructures Design

ideaForge

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 Defense, Paramilitary, and Police forces ensure citizen safety and save lives.

Position Overview

We are seeking a passionate and driven Engineer-II – Aerostructures Design to join our R&D Mechanical team. This role focuses on hands-on aerostructure design, combining design engineering with the ability to interpret 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 design optimization, physical validation, and continuous improvement activities.

ROLE VISION / PURPOSE

To design, develop, optimize, and sustain lightweight, robust aerostructures and composite systems for UAV platforms by leveraging structural design principles, interpreting FEA simulation findings, and supporting physical validation — ensuring product readiness, structural reliability, certification compliance, and continuous improvement aligned with market and organizational goals.

Cross-Functional Stakeholders: Aerostructures Design Team | V&V Team | Manufacturing | Operations | IFT & CFT Teams (Propulsion, Payload, Electronics) | Procurement | Sales & Applications | Project & Product Management

Key Responsibilities

Aerostructure Design & Development
Design and develop composite and metallic aerostructures including wings, fuselage, empennage, landing legs, hinges, and gliders.
Perform aero sizing and structural sizing calculations for lightweight optimization across UAV platforms.
Create CAD models and detailed engineering drawings adhering to DFMA principles.
Support Engineering Pilots (EPs), NCNC trials, and Product Readiness Reviews (PRRs).

Key Outcomes: Lightweight, structurally robust airframe designs; on-time design release; improved structural performance and manufacturability.

Tooling & Assembly Definition (TAD) & PLM Support

Apply Tooling & Assembly Definition (TAD) principles to assist in defining assembly strategies, jigs, and fixture interfaces for aerostructures.
Prepare detailed assembly BOMs and support design-for-assembly (DFA) planning.
Utilize PLM systems (e.g., Windchill) for revision control, digital thread management, part structures, and release workflows.

Key Outcomes: Streamlined assembly processes; accurate assembly BOMs; seamless PLM integration and version control.

Composite Engineering & Material Optimization
Design composite parts and analyze layup feasibility; perform draping and structural optimization for weight reduction.
Evaluate and select composite materials and manufacturing processes (hand lay-up, prepreg, RTM, etc.).
Apply Classical Laminate Theory (CLT) and ply optimization to achieve required stiffness-to-weight targets.
Ensure reliable composite parts with improved manufacturability and reduced prototype failures.

Key Outcomes: Optimized strength-to-weight ratio; validated laminate stability; reduced development iterations.

3. Vibration & Dynamic Design Review
Review and interpret vibration simulation results 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.
Collaborate with simulation specialists to translate FEA insights into actionable structural design modifications.

Key Outcomes: Clear natural frequency separation from excitation sources; reduced resonance risk; identification of critical excitation zones.

4. Structural Strength, Durability & Design Optimization
Incorporate static, non-linear, and buckling simulation outcomes into CAD models under operational and extreme load cases.
Utilize FEA simulation outputs to optimize composite layups, laminate definitions, and structural stability.
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).

Key Outcomes: Validated structural safety margins; optimized stiffness-to-weight ratio; weight reduction without integrity compromise.

Physical Validation, CAE Correlation & RCA
Support physical validation activities including tap tests (modal validation), in-flight vibration data analysis, drop test validation, and static load testing.
Assist in CAE–test correlation to validate simulation models against physical test results.
Conduct Root Cause Analysis (RCA) and implement Corrective & Preventive Actions (CAPA) for field failures and structural issues.
Track and close RCA learnings to achieve measurable improvement in field failure metrics.

Key Outcomes: Strong CAE–test correlation; improved structural reliability; minimum 50% improvement vs. prior year failure metrics; reduced redesign cycles.

Certification Support & Documentation
Assist in preparing structural validation reports and compliance documentation for Type & Military Certification.
Maintain CAD models, GD&T drawings, BOMs, simulation reports, and design documentation.
Participate in design reviews and ensure drawing release accuracy and configuration management.

Key Outcomes: Timely and audit-ready structural documentation; accurate drawing release; standardized engineering processes.

Manufacturing Optimization & Indigenization
Support vendor development and indigenization initiatives to reduce import dependency.
Drive Value Addition / Value Innovation (VA/VI) through design and sourcing optimization.
Introduce advanced composite manufacturing techniques to improve quality and cycle time.

Key Outcomes: Cost reduction through VA/VI; increased indigenous sourcing; improved production efficiency.

Additive Manufacturing & Rapid Prototyping

Leverage 3D printing techniques (FDM, SLA, SLS, MJF, etc.) for rapid prototyping and lightweight structural component evaluation.
Select suitable additive manufacturing processes, material options, and post-processing methods tailored for specific aerostructure applications.

Key Outcomes: Faster prototyping iterations; optimal selection of additive manufacturing methods for development and tooling needs.

Cross-Functional & Organizational Contribution
Provide technical support to Sales & Project Management teams.
Participate in flight trials and tech-driven swim lanes (propulsion, payload vibrations, aerostructure).
Support development of design guidelines, SOPs, material databases, and cross-functional engineering processes.
Participate in skill training, conferences, and Knowledge Management (KM) sessions.
Contribute towards at least one Intellectual Property (IP) per year.

Key Outcomes: Smooth cross-functional collaboration; reduced analysis cycle time; standardized simulation framework; at least one IP contribution.

DESIRED BEHAVIOURAL VALUES

Commitment to common purpose and goals
Respect for colleagues and stakeholders at every level
Displaying integrity and ethics in all actions
Taking initiative and ownership with accountability
Being passionate about making a difference
Maintaining and managing harmonious interpersonal relationships