ideaForge is the leader in industrial and surveillance UAV manufacturing in India with more than 50% market share. ideaForge co-designed India's first Surveillance quadrotor UAV, NETRA with the Defense Research & Development Organization (DRDO) and is also responsible for engineering the then world's lightest Autopilot.
ideaForge develops completely indigenous technology for Unmanned Aerial Systems (UAS). Our in-house R&D;, design, manufacturing, software, services and training operations give us the flexibility to customize products for an array of requirements. We are continually innovating and experimenting to transform our aerial platforms to offer greater performance, higher reliability and autonomy.
With this philosophy, we have consistently helped Indian Defense, Paramilitary & Police forces ensure the safety of our citizens and ultimately save precious lives.
We are seeking a tech Lead – ESS to join our dynamic and interdisciplinary UAV engineering team. The ideal candidate will be responsible for the ESS design and development of Hybrid UAV systems, with an emphasis on design excellence, manufacturability, integration readiness, and cross-functional collaboration. The candidate should bring deep experience in CAD design, tooling & assembly definition (TAD), PLM integration, material-process compatibility, and should be capable of taking end-to-end mechanical ownership from design to delivery.
Mechanical and Electrical
Develop electrical battery pack architecture including cell configuration (series/parallel), interconnects, busbars, protection circuitry, fusing, current sensing, balancing, and BMS integration.
Establish battery pack validation strategy covering functional, environmental, thermal, vibration, abuse, transportation, and lifecycle qualification testing.
Mechanical Design & CAD Ownership
Lead the mechanical design of battery packs, battery enclosures,



mounting systems, connectors, charging interfaces, and serviceability features using advanced parametric CAD tools (preferably PTC Creo).
Develop and maintain complex CAD assemblies, design trees, manufacturing drawings, and configuration management across product variants.
Perform tolerance stack-up analysis and optimize packaging for manufacturability and assembly.
Electrical Integration & Battery Management Systems
Develop battery electrical schematics including high-current distribution, protection devices, contactors, pre-charge circuits, balancing circuits, and charging interfaces.
Cell voltage monitoring
Temperature monitoring
Ensure compliance with electrical safety standards including insulation coordination, creepage, clearance, and fault protection.
Work closely with embedded electronics teams for BMS hardware and firmware integration.
Perform battery thermal analysis under mission-specific duty cycles.
Evaluate and mitigate risks associated with thermal runaway, propagation, gas venting, internal short circuits, and abuse conditions.
Solid knowledge of materials (metals, polymers, composites) with a clear understanding of process-specific constraints.
Prior experience working with high-performance materials, injection molding, and machining processes is advantageous.
Manufacturing Engineering & Assembly Definition (TAD)
Define battery manufacturing and assembly processes including cell matching, welding, bonding, potting, fastening,



insulation, and sealing.
Develop assembly BOMs, work instructions, tooling, fixtures, and end-of-line test processes.
Work closely with systems engineering, integration, sourcing, testing, and manufacturing teams.
Take ownership of the design deliverables, resolve cross-domain design issues, and ensure on-time maturity of the mechanical stack.
Support V&V; (Validation & Verification) activities and ensure that mechanical designs are compliant with technical specs and regulatory needs.
Root Cause Analysis
Investigate battery failures through detailed mechanical, electrical, thermal, and electrochemical analysis.
Correlate test data, field returns, manufacturing observations, and simulation results to identify root causes.
Drive continuous improvements in battery performance, safety, reliability, and manufacturability.
Bachelor''s or Master''s degree in Electrical Engineering, Mechanical Engineering, Energy Engineering, Mechatronics, Automotive Engineering, Aerospace Engineering, or a related discipline.
Tech./Strong understanding of lithium-ion battery technologies (NMC, LFP, LMFP, High-Nickel, etc.).
Hands-on experience in battery pack mechanical and electrical design.
Experience with thermal analysis and battery safety engineering.
Proficiency in CAD tools (PTC Creo preferred).
Knowledge of manufacturing processes including laser welding, ultrasonic welding, busbar design, adhesives, potting, injection molding, CNC machining, and additive manufacturing.
Experience with DFMEA, PFMEA, Design Validation Plans (DVP&R;), reliability engineering, and Root Cause Analysis.
Demonstrated experience leading multidisciplinary engineering teams.
Effective collaboration across design, manufacturing, quality, sourcing, and program management teams.

📌 Tech Lead Testing (Mumbai)
🏢 IdeaForge
📍 Mumbai