Design Engineer

2 days ago

Thiruvananthapuram, Kerala, India IMG-IN Full time ₹ 15,00,000 - ₹ 25,00,000 per year

In this role, you will be responsible for end-to-end mechanical design from initial concept to final launch of equipment for plastic welding, finishing, and testing. You will also work closely with the controls team, manufacturing, and suppliers to develop systems that are robust, safe, and deliver high uptime.

What you'll work on

  • Plastic hot plate welding systems and tooling (platens, nests, clamps)
  • Ultrasonic punching/welding (horns, fixtures, anvils, stack integration)
  • Plastic fuel tank welding and assembly equipment
  • Plastic spin welding tooling and machines
  • Deburr and polishing stations/automation
  • Leak test systems (pressure decay, mass flow) and sealing fixtures
  • Edge wrapping machines (tooling, feed, adhesive application)
  • Injection mold tending, including insertion and EOAT/robot gripper design

Responsibilities

  • Convert URS/SOW into concepts, layouts, and cycle-time estimates.
  • Design machines, fixtures, nests, EOAT, guarding, pneumatics, and motion subsystems.
  • Perform tolerance stacks and apply GD&T; select materials and components.
  • Produce 3D models, detail drawings, and BOMs; manage PDM/ECNs.
  • Collaborate with controls on sensors, I/O, PLC/HMI, safety, and data needs.
  • Vendor sourcing, DFM/DFA, build support, FAT/SAT, installation, and commissioning.
  • Develop and document process windows, DOE, and validation (IQ/OQ/PQ); train users.

Qualifications

  • BE in Mechanical/Manufacturing Engineering (or equivalent experience)
  • 5+ years designing custom automation and/or plastic joining equipment
  • Hands-on experience with: Plastic Joining, ultrasonic punching/welding, fricition welding, leak testing, deburr/polish, edge wrapping, and injection mold tending with insertion
  • Proficiency in 3D CAD (SolidWorks/Inventor/CATIA/NX)
  • Strong fixture/machine design, pneumatics, motion components, and safety design

Nice to have

  • Plastic fuel tank assembly line experience (automotive APQP/PPAP)
  • Robot integration (FANUC/ABB/KUKA), vision.
  • FMEA, risk assessment (ISO 12100), CE/OSHA compliance.
  • Leak test instrumentation (e.g., ATEQ/InterTech), thermal/FEA simulation

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