Roles & responsibilities of UAV Design Engineer

Design & Modeling
Design, model, and draft 3D components and assemblies for UAV airframes, payload mounts, and supporting mechanical systems using CAD tools like SolidWorks, Fusion 360, or CATIA.
Develop lightweight and manufacturable drone parts using advanced materials such as carbon fiber, composites, and high-performance polymers.
Create detailed 2D technical drawings with GD&T annotations, BOMs, and assembly documentation for production and quality inspection.
Maintain revision control of CAD files, ensuring adherence to internal quality and regulatory standards.

System Integration & Testing
Integrate advanced flight control systems, navigation modules, and payloads into airframe designs with strong attention to mechanical and electrical compatibility.
Perform detailed mechanical assembly, calibration, and tuning of UAV platforms during R&D, prototyping, and production phases.
Diagnose and resolve complex system-level issues involving drone mechanics, electronics, propulsion, and control systems.
Support product validation by participating in field testing, critical deployments, demonstrations, and trials, providing engineering feedback for mechanical and system enhancements.
Provide technical insights during field missions and work closely with operations teams to ensure mission success.

Analysis & Optimization
Optimize mechanical designs for performance, weight reduction, ease of manufacturing (DFM/DFA), cost efficiency, and maintainability.
Conduct structural, thermal, and vibration simulations (FEA) to validate design robustness and operational reliability.
Research and evaluate emerging materials, technologies, and components to enhance drone systems' performance and durability.

Collaboration & Support
Work closely with electronics, propulsion, aerodynamics, and software teams to ensure seamless integration of all system components.
Coordinate with external vendors and manufacturing partners for prototyping, tooling, component sourcing, and fabrication updates.
Support internal teams with iterative design improvements, tooling adjustments, and rapid prototyping needs throughout product development cycles.
Create and maintain comprehensive technical documentation including design specifications, test reports, assembly manuals, and troubleshooting guides.
Provide expert-level design support and technical troubleshooting for client deployments or special mission requirements when needed.

Required Qualifications
Education: Bachelor’s degree in Mechanical, Aerospace, Mechatronics, or a related engineering discipline.
CAD Proficiency: Minimum 2+ years of hands-on experience in CAD design for UAVs, robotics, or precision mechanical systems.
Software Skills: Expert proficiency in a major CAD software package such as SolidWorks, CATIA, Autodesk Inventor, or Fusion 360.
Manufacturing & Materials: Strong understanding of materials, manufacturing processes (CNC, injection molding, 3D printing), and tolerancing/GD&T.
System Knowledge: Proven experience or strong familiarity with drone assembly, testing methodologies, flight control principles, and sensor/payload integration.
Soft Skills: Excellent problem-solving, visualization, and teamwork skills with a keen attention to detail.