Engineer II -Aerostructures Design

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
  
  

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