Mechanical Design Engineer

Chennai, Tamil Nadu

Work Type: Full Time

Location: The ePlane Company, IIT Madras Discovery Campus, Chennai – 603103

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.