We are seeking a
Senior Manufacturing Engineer – Mechanical to lead the manufacturing and physical integration of our UAV platforms. This is a critical execution role where you will be responsible for translating complex technical packages into flight-ready hardware. you will bridge the gap between digital design and physical assembly. You will lead the mechanical building while working in a
co-ownership model with the Systems Engineering team to ensure the seamless physical integration of avionics and electronic payloads into the airframe. while establishing and driving standardized manufacturing processes, work instructions, and assembly methodologies. The role also includes ownership for creation of Manufacturing BoM & management (Product Tree), engineering change management (ECO/ECR), and release processes, ensuring configuration control, traceability, and alignment between design and production.
Key Responsibilities
- Lead the end-to-end mechanical assembly of UAV airframes, ensuring all units meet stringent design tolerances and structural requirements
- Convert engineering data into optimized Production Workflows, including detailed assembly sequences and quality-gated work instructions.
- Manage the fabrication and fitment of major components, including composite structures, propulsion systems, and flight control surfaces
- Responsible with the Systems team to co-own the internal integration. And responsible for the mechanical integrity of the electronics suite, including vibration isolation, thermal management (ducts/heatsinks), and secure mounting
- Design and implement structural routing for wire harnesses and connector interfaces to ensure they are protected from mechanical wear and environmental factors.
- Lead Fit-Check audits to ensure that the airframe and internal systems are perfectly harmonized before final closure.
- Maintain hands-on proficiency in SolidWorks to design and maintain production-critical tooling, such as assembly jigs, alignment fixtures, and drilling templates.
- Update 3D models and 2D drawings to reflect as-built production realities, ensuring that the Master Bill of Materials (BOM) is always accurate.
- Utilize CAD to perform tolerance stack-up analysis, ensuring repeatability across serial production runs.
- Oversee critical mechanical milestones, including wing-to-fuselage joining, landing gear deployment testing, and Center of Gravity (CG) verification.
- Establish and enforce standards for aerospace-grade bonding, torquing, and fastener security (e.g., safety wiring/torque-stripping).
- Conduct Root Cause Analysis (RCA) for any mechanical discrepancies identified during the build or ground-testing phases.
Skills and competencies –
- B.E./B. Tech in Mechanical, Aerospace, Mechatronics Engineering or Equivalent.
- 5–8 years of experience in high-precision mechanical production (Automobile, Aerospace, Defense, or Robotics).
- Strong knowledge of SolidWorks (Assemblies, Sheet Metal, and Tooling Design).
- Strong Knowledge of Machining, Additive Manufacturing and Assembly Process.
- Deep understanding of GD&T (Geometric Dimensioning and Tolerancing).
- Experience with advanced composites (Carbon Fiber) and aerospace-grade alloys.
- Proven ability to manage the physical interface between mechanical structures and sensitive electronic components.
- Failure Mode and Effects Analysis (DFMEA/PFMEA)
- A track record of complex technical documentation and successfully operationalizing it on a shop floor.
- Strong knowledge of Lean Manufacturing principles (Kaizen, 5S, Value Stream mapping)
