Fixed-Wing UAV Design Engineer – Airframe & Mechanical Systems

? [Thanjavur, Tamil Nadu] | Full-Time

We are looking for an experienced Fixed-Wing UAV Design Engineer to design and develop lightweight, robust, and production-ready UAV airframes and mechanical systems.

The role will focus on composite airframe design, mould/tooling design, critical mechanical interfaces, modular airframe architecture, and payload integration, working closely with Aerodynamics, Composites, Avionics, Manufacturing, and Flight Test teams.

Key Responsibilities

- Design and develop fixed-wing UAV airframes, including fuselage, wings, empennage, control surfaces, hatches, and internal structures.
- Design composite structures using CFRP/GFRP, sandwich panels, foam/honeycomb cores, and bonded assemblies.
- Optimise airframes for weight, strength, stiffness, aerodynamic requirements, manufacturability, and serviceability.
- Design composite moulds, master patterns, assembly fixtures, bonding fixtures, and manufacturing tooling.
- Develop critical mechanical interfaces such as wing-fuselage joints, quick-release mechanisms, locking systems, hinges, control linkages, landing interfaces, and structural connectors.
- Design modular airframe architectures for rapid assembly, transportation, maintenance, and field replacement.
- Develop mechanical integration solutions for modular payloads, EO/IR systems, sensors, antennas, avionics, batteries, and mission equipment.




- Ensure payload integration considers CG, structural loads, vibration isolation, accessibility, thermal requirements, and cable routing.
- Perform GD&T;, tolerance stack-up, structural calculations, mass/CG analysis, and design reviews.
- Work closely with the Composite Fabrication Team to take designs from CAD → mould/tooling → prototype → assembly → flight testing → production.
- Support prototype builds, ground testing, flight testing, failure analysis, and iterative design improvements.
- Prepare complete 3D CAD, manufacturing drawings, BOMs, assembly drawings, and engineering documentation.

Requirements
- Bachelor's/Master's degree in Aerospace, Aeronautical, Mechanical, or related Engineering.
- 3+ years of hands-on experience in UAV, aerospace, or aircraft mechanical/airframe design.
- Strong experience in fixed-wing UAV design and composite airframe structures.
- Robust proficiency in CATIA / SolidWorks
- Experience with composite mould/tooling design and composite manufacturing processes.
- Strong understanding of GD&T;, tolerance stack-up, structural joints, fasteners, bonding, machining, and manufacturing processes.
- Experience designing mechanical interfaces, modular assemblies, and payload integration systems.
- Good understanding of aircraft loads, weight & balance, CG, structural design, vibration, and DFM/DFA.

📌 Fixed-Wing UAV Design Engineer – Airframe & Mechanical Systems (Thanjavur)
🏢 Yali Aerospace
📍 Thanjavur