We are looking for an experienced Sr. Mechanical Tool Design Engineer to design and develop production tooling, jigs, fixtures, moulds, and assembly aids for VTOL-Fixed wing UAV manufacturing. The role requires robust mechanical design expertise and hands-on involvement from concept through manufacturing and shop-floor validation.
Key Responsibilities
Design jigs, fixtures, moulds, assembly tools, drilling/trimming fixtures, and inspection tooling.
Develop tooling for UAV structures, composite parts, mechanical assemblies, and production processes.
Design composite moulds and bonding/assembly fixtures for wings, fuselage, control surfaces, and other airframe components.
Perform tolerance stack-up, GD&T;, fitment, and manufacturability analysis.
Select appropriate tooling materials and manufacturing processes.
Create detailed 3D CAD models, 2D drawings, BOMs, and manufacturing documentation.
Work closely with Design, Manufacturing, Quality, and Production teams.
Support tool manufacturing, assembly, trials,



inspection, troubleshooting, and design modifications.
Improve tooling for accuracy, repeatability, ergonomics, cycle time, and production efficiency.
Mentor junior engineers and drive tooling design standards and best practices.
Requirements
Bachelor's/Diploma in Mechanical, Production, Manufacturing, Tool & Die Engineering, or related field.
5+ years of relevant tooling/mechanical design experience.
Strong proficiency in 3DS CATIA or SolidWorks
Strong understanding of GD&T;, tolerance stack-up, machining, fabrication, composites, and manufacturing processes.
Experience designing production jigs, fixtures, moulds, and assembly tooling.
Strong hands-on problem-solving and shop-floor troubleshooting skills.
Experience in UAV, aerospace, automotive, composites, or precision manufacturing is preferred.

📌 Senior Mechanical Tool Design Engineer (Thanjavur)
🏢 Yali Aerospace
📍 Thanjavur