Job Title: Surface Design Engineer – Protective Gear / Helmets

Department: Product Design & Engineering / R&D;

Employment Type: Full-Time

Location: KPHB 9th Phase, Hyderabad

Salary: 25000-35000

Role Overview

We are seeking a skilled Surface Design Engineer with specialized
expertise in complex surface modeling and product development for helmets
(motorcycle, cycling, industrial, or athletic protective gear). In this role,
you will bridge the gap between industrial design concepts and manufacturing
reality by creating production-ready, Class-A surfaces, optimizing aerodynamic
profiles, and ensuring compliance with global safety standards.

Key Responsibilities

· Class-A Surfacing: Develop, refine, and maintain high-quality Class-A aesthetic surfaces based on industrial design sketches, clay scan data (reverse engineering), and ergonomic constraints.

· Helmet Component Modeling: Model full helmet assemblies including outer shells (polycarbonate, fiberglass, carbon fiber), multi-density EPS liners, visors/face shields, ventilation channels, and retention mechanisms.

· Design for Manufacturing (DFM): Ensure all surface models account for injection molding, compression molding, draft angles, parting lines, split lines, tooling feasibility, and uniform wall thickness.

· Kinematics & Mechanism Design: Design and integrate moving components such as visor pivot systems, sun visors, breath guards, and intake/exhaust vents.

· Regulatory Compliance Integration: Collaborate with CAE and testing teams to incorporate impact zones, headform clearance geometries, and safety certification requirements (e.g., DOT, ECE 22.06, SNELL, CPSC, or ISI standards).





· Cross-Functional Collaboration: Partner closely with Industrial Designers, Tooling Engineers, Aerodynamicists (CFD), and Prototyping teams from initial concept to pilot production.

Required Qualifications & Skills

· Education: Bachelor’s degree in Mechanical Engineering, Automotive Design, Product/Industrial Design, or a related engineering discipline.

· Experience: 2+ years of hands-on CAD surfacing experience, with a strong portfolio showcasing helmet or complex organic consumer protective gear design.

· CAD Proficiency: Mastery in high-end surfacing software such as CATIA (Generative Shape Design / Freestyle / ICEM Shape Design), Autodesk Alias, SolidWorks (Advanced Surfacing), or PTC Creo.

· Surface Continuity: Deep technical understanding of G0, G1, G2, and G3 curvature continuity and surface diagnostic tools (zebra striping, curvature analysis).

· Tooling Knowledge: Practical knowledge of plastic injection molding, thermoforming, and composite layup processes.

· Reverse Engineering: Experience working with 3D scan data (point clouds/meshes) using tools like Geomagic Design X or CATIA Digitized Shape Editor.

Preferred Qualifications

· Prior experience with optical-grade visor curvature and distortion minimization.

· Familiarity with CFD wind tunnel testing for aero-acoustic noise reduction and aerodynamic drag optimization.

· Hands-on experience with rapid prototyping (SLA/SLS/FDM 3D printing) for ergonomic fit checks.

Pay: ₹25,000.00 - ₹35,000.00 per month

Perks:

- Cell phone reimbursement
- Commuter assistance
- Flexible schedule
- Food provided
- Health insurance
- Paid sick time
- Provident Fund

Work Location: In person

📌 Surface Design Engineer – Protective Gear / Helmets (Kukatpally Housing Board Colony)
🏢 ASTHRA PROJECTS
📍 Kukatpally Housing Board Colony