Location: The ePlane Company, IIT Madras Discovery Campus, Chennai 603103
Experience Level: 25 years (hands-on design & development experience)
About the Role:
We are looking for a highly capable Mechanical Engineer with hands-on experience in CAD
and detailed mechanical design to join our electric Powertrain Team. The role involves
working on the design, modeling, and integration of propulsion components, with a specialized
focus on rotating machinery such as motors, inverters, and gearbox transmissions for
advanced aerial mobility platforms and eVTOL aircraft.
Key Responsibilities (Mechanical Focus)
- Create and manage 3D CAD models and 2D drawings of powertrain components, with
a focus on rotating assemblies (e.g., motor shafts, rotor/stator housings, high-speed
gear sets, complex gearbox casings, bearings, and sealing systems).
- Develop gearbox layouts, transmission systems, and perform detailed tolerance stack-
up analyses to ensure component interaction and function.
- Apply Geometric Dimensioning and Tolerancing (GD&T) and DFM/DFA principles to
ensure robust manufacturability and assembly feasibility.
- Perform load, stress, and deflection calculations for critical rotating parts (e.g.,
shafts, gears, bearings) to determine safety factors and material requirements.
- Conduct mechanical design activities for electric motor development, including
structural design, containment analysis, and support for rotor dynamics analysis.
- Collaborate with electrical and thermal teams for mechanical-electrical-thermal
integration, including liquid/oil cooling flow path design within motor/inverter enclosures.
- Provide CAD support for FEA/thermal simulations and iterate designs based on analysis
feedback (e.g., vibration, fatigue, and thermal stress).
- Work with suppliers and vendors on prototype manufacturing, precision machining, and
assembly of complex powertrain components.
- Participate in design reviews and documentation control for aerospace compliance.
- Support test and validation activities, including prototype assembly, rig testing, and
troubleshooting for high-speed rotating systems.
Required Skills & Qualifications
- B.E./B.Tech/M.E./M.Tech in Mechanical, Automotive, or Aerospace Engineering.
- 25 years of relevant experience in mechanical design, with a strong preference for
EV, aerospace, or automotive powertrain.
- Proven relevant work experience in Rotating Machinery/Equipment (e.g.,
transmissions, compressors, high-speed pumps, or electric motors).
- Strong proficiency in CAD tools (SolidWorks, CATIA, NX, Creo, or equivalent).
- Expert knowledge of gearbox/transmission design, bearing systems selection,
and sealing technologies.
- Expertise in GD&T, detailed tolerance analysis, and familiarity with standards (e.g.,
ISO/AGMA gear standards).
- Demonstrated ability to perform mechanical load, torque, and stress calculations
for motor and gearbox components.
- Exposure to thermal management systems (liquid/oil cooling, heat exchangers)
specifically for high-power electric components.
- Understanding of manufacturing processes precision machining, casting, and
additive manufacturing.
Preferred (Good To Have)
- Experience with high-power electric motor/inverter packaging (200 kW+).
- Exposure to FEA/CAE tools (ANSYS, SimScale, etc.) for structural, thermal, and
dynamic analysis.
- Knowledge of aerospace/aviation standards (RTCA DO-160G, DO-254, MIL-STD).
- Hands-on involvement in prototype assembly, balancing, and rig testing of rotating
equipment.
What We Offer:
- Opportunity to work on cutting-edge eVTOL propulsion technology.
- Dynamic environment at IIT Madras Discovery Campus.
- Competitive compensation with career growth opportunities.
- Exposure to end-to-end design, development, testing, and certification workflows in
aerospace mobility.
