UAV Design Engineer

Company Description

Aerial IQ is a pioneering aerospace solutions provider specializing in unmanned aerial systems (UAS). With a focus on innovation, the company is committed to designing and developing indigenous UAS while leveraging emerging technologies to shape the future of aerospace. Aerial IQs flagship product, "Aviral," a tethered drone, reflects the team's dedication to crafting high-quality, future-ready solutions. Backed by years of expertise in the aerospace industry, Aerial IQ is driven by a shared passion for innovation and excellence.

Role Description

This is an internship, on-site role located in Gurugram for a UAV Design Engineer. The chosen candidate will engage in designing, developing, and optimizing components and systems for unmanned aerial vehicles (UAVs). Responsibilities include creating and enhancing UAV designs, performing computer-aided simulations, collaborating with cross-functional teams on electrical and mechanical systems, and ensuring compliance with industry standards. The candidate will also contribute to the end-to-end product lifecycle, from conceptual design to deployment.

Essential Duties and Responsibilities:

• Design and develop drone airframes, structural components, and mechanical assemblies.
• Work on complete UAV system integration, including propulsion system, payload integration, landing gear, battery systems, and electronics housing.
• Perform concept design, CAD modelling, and design optimisation for performance, weight, and durability.
• Ensure designs are optimised for efficient manufacturing and large-scale production.
• Work closely with the production team to implement design improvements to enhance manufacturability and reduce costs.
• Select appropriate materials, fabrication techniques, and tolerances.
• The candidate should have knowledge of:

1. CNC machining
2. Injection molding
3. Composite manufacturing (carbon fibre, fibreglass)
4. 3D printing / additive manufacturing
5. Sheet metal fabrication
6. Casting and extrusion
7. Surface finishing and coating processes
8. Design components with ease of assembly, serviceability, and maintenance in mind.
9. Define assembly sequence and procedures.
10. Create detailed manufacturing drawings and assembly documentation.

• Proficiency in 3D CAD design software such as SolidWorks, Creo, CATIA, or Fusion 360 for complex mechanical assemblies and UAV structural design.
• Experience in creating production-ready CAD models, manufacturing drawings, assembly drawings, and Bill of Materials (BOM).
• Working knowledge of engineering simulation tools such as ANSYS or SolidWorks Simulation for structural and vibration analysis.

Requirements:

• Experience in mechanical/product design, preferably in UAV, aerospace, robotics, automotive, or high-performance electromechanical systems.
• Proven experience in designing and developing drone airframes or UAV mechanical systems, including frame structures, propulsion integration, payload mounts, and battery integration.
• Hands-on experience in taking products from concept design to prototype and production, with strong understanding of the complete product development lifecycle.
• Practical experience with manufacturing processes such as CNC machining, composite (carbon fiber) fabrication, sheet metal fabrication, injection molding, and additive manufacturing.
• Experience in Design for Manufacturing (DFM) and Design for Assembly (DFA) to ensure designs are optimized for production, reliability, and cost efficiency.
• Hands-on experience in prototype development, testing, and iterative design improvements, including troubleshooting structural and vibration-related issues in UAV systems.