Mechanical Design Engineer

Location: The ePlane Company, IIT Madras Discovery Campus, Chennai –   Experience Level: 2–5 years (hands-on design & development experience) About the Role:   We are looking for a highly capable Mechanical Engineer with hands-on experience in CAD   and detailed mechanical design to join our electric Powertrain Team. The role involves   working on the design, modeling, and integration of propulsion components, with a specialized   focus on rotating machinery such as motors, inverters, and gearbox transmissions for   advanced aerial mobility platforms and eVTOL aircraft. Key Responsibilities (Mechanical Focus)   ● Create and manage 3D CAD models and 2D drawings of powertrain components, with   a focus on rotating assemblies (e.g., motor shafts, rotor/stator housings, high-speed   gear sets, complex gearbox casings, bearings, and sealing systems).   ● Develop gearbox layouts, transmission systems, and perform detailed tolerance stack-   up analyses to ensure component interaction and function.   ● Apply Geometric Dimensioning and Tolerancing (GD&T) and DFM/DFA principles to   ensure robust manufacturability and assembly feasibility.   ● Perform load, stress, and deflection calculations for critical rotating parts (e.g.,   shafts, gears, bearings) to determine safety factors and material requirements.   ● Conduct mechanical design activities for electric motor development, including   structural design, containment analysis, and support for rotor dynamics analysis.   ● Collaborate with electrical and thermal teams for mechanical-electrical-thermal   integration, including liquid/oil cooling flow path design within motor/inverter enclosures.   ● Provide CAD support for FEA/thermal simulations and iterate designs based on analysis   feedback (e.g., vibration, fatigue, and thermal stress).   ● Work with suppliers and vendors on prototype manufacturing, precision machining, and   assembly of complex powertrain components.   ● Participate in design reviews and documentation control for aerospace compliance.   ● Support test and validation activities, including prototype assembly, rig testing, and   troubleshooting for high-speed rotating systems. Required Skills & Qualifications   ● B.E./B.Tech/M.E./M.Tech in Mechanical, Automotive, or Aerospace Engineering.   ● 2–5 years of relevant experience in mechanical design, with a strong preference for   EV, aerospace, or automotive powertrain.   ● Proven relevant work experience in Rotating Machinery/Equipment (e.g.,   transmissions, compressors, high-speed pumps, or electric motors).   ● Strong proficiency in CAD tools (SolidWorks, CATIA, NX, Creo, or equivalent).   ● Expert knowledge of gearbox/transmission design, bearing systems selection,   and sealing technologies.   ● Expertise in GD&T, detailed tolerance analysis, and familiarity with standards (e.g.,   ISO/AGMA gear standards).   ● Demonstrated ability to perform mechanical load, torque, and stress calculations   for motor and gearbox components.   ● Exposure to thermal management systems (liquid/oil cooling, heat exchangers)   specifically for high-power electric components.   ● Understanding of manufacturing processes – precision machining, casting, and   additive manufacturing. Preferred (Good to Have)   ● Experience with high-power electric motor/inverter packaging (200 kW+).   ● Exposure to FEA/CAE tools (ANSYS, SimScale, etc.) for structural, thermal, and   dynamic analysis.   ● Knowledge of aerospace/aviation standards (RTCA DO-160G, DO-254, MIL-STD).   ● Hands-on involvement in prototype assembly, balancing, and rig testing of rotating   equipment. What We Offer:   ● Opportunity to work on cutting-edge eVTOL propulsion technology.   ● Dynamic environment at IIT Madras Discovery Campus.   ● Competitive compensation with career growth opportunities.   ● Exposure to end-to-end design, development, testing, and certification workflows in   aerospace mobility.