Design Manager – Structural Design (Mechanical)

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1. Role Purpose

To lead the structural mechanical design function for complex, high-load-bearing components and assemblies used in aerospace and defense applications. This role requires proficiency in aerospace-grade design standards, mechanical integrity analysis, and team leadership to deliver designs that meet stringent performance, reliability, and compliance requirements.

2. Key Responsibilities

A. Structural Design Engineering – Aerospace & Defense Focus

• Lead the structural design of aerospace components (e.g., brackets, fixtures, mounts, frames, nacelles, launch structures, UAV parts, shelters, etc.) considering weight, vibration, fatigue, and aerostructure integrity.

• Interpret customer specifications (e.g., DRDO, ISRO, HAL, ADA, BEML, BEL) and ensure end-to-end design compliance.

• Develop static, dynamic, and modal loading conditions based on defense and flightworthiness requirements.

B. Design Execution & Validation

• Prepare and approve 3D models, 2D drawings, BOMs, GD&T, tolerance stack-ups using industry-standard CAD tools (e.g., CATIA, SolidWorks, NX).

• Collaborate with FEA experts or perform simulations for stress, vibration, buckling, fatigue life using tools such as ANSYS, Abaqus, HyperMesh.

• Ensure design validation through CAE and physical testing protocols (e.g., strain gauge analysis, modal testing, etc.).

C. Standards, Compliance & Documentation

• Ensure compliance with ASME, ASTM, IS, MIL, or Eurocode standards and customerspecific aerospace/defense norms.

• Apply knowledge of aerospace materials (e.g., aluminum alloys, titanium, Inconel, composites) and their behavior under extreme environmental conditions.

• Maintain design records as per ISO 9001, AS9100, or CEMILAC/DGAQA/DGQA requirements.

• Review and approve Design Failure Mode and Effects Analysis (DFMEA), technical design dossiers, and ECNs.

D. Project Management & Cross-functional Collaboration

• Work closely with production, QA/QC, supply chain, and program management teams for seamless transition from design to manufacturing.

• Ensure timely delivery of design milestones, support in procurement of special materials or hardware.

• Coordinate with vendors for fabrication feasibility, special process approvals, and reverse engineering where applicable.

E. Leadership & People Development

• Manage a team of design engineers, draftsmen, and analysts.

• Provide technical guidance, design reviews, mentorship, and career development support.

• Create a strong design governance process including checklists, review gates, and signoff protocols.

• Foster innovation in lightweighting, design optimization, manufacturability, and digital design integration.

3. Educational Qualifications

• Essential: B.E. / B.Tech in Mechanical Engineering / Aeronautical Engineering / Structural Engineering

• Preferred: M.E. / M.Tech in Design Engineering / Aerospace Structures / Applied Mechanics

• Certifications: CAD (CATIA/NX/SolidWorks), FEA (ANSYS/Abaqus), familiarity with AS9100 or CEMILAC standards preferred

4. Experience Requirements

• Minimum 10 years of experience in mechanical structural design, with at least 5 years in aerospace/defense design projects.

• Proven experience with load-bearing assemblies, sheet metal structures, machined frames, and precision fabrication components.

• Experience in missile systems, aerospace platforms, UAV design, ground-based mobile defense systems, or launch vehicles highly desirable.

• Direct exposure to customer audits from DRDO, ISRO, HAL, or Tier-1 defense suppliers is a strong advantage.