UAV Design & Additive Manufacturing Engineer

UAV Design & Additive Manufacturing Engineer
Unmanned Systems | Enhansafe India Pvt. Ltd.
Location: Pune (full-time, on-site) Experience: 3–5 years Domain: Defence-grade UAV platforms
ABOUT ENHANSAFE
Enhansafe India Pvt. Ltd. is a deeptech defence and homeland security company focused on unmanned aerial systems and indigenous drone manufacturing. We build mission-ready platforms for defence and security users, and we are expanding our UAV design team.
ROLE OVERVIEW
Own the mechanical design of our unmanned platforms, from concept and CAD to flight-ready hardware. You will design multicopter and fixed-wing VTOL airframes, build and iterate them through in-house additive manufacturing, and keep our 3D printing lab running at production standard.
KEY RESPONSIBILITIES
Design & Structural Engineering
· Design multicopter frames and fixed-wing VTOL airframes, including booms, fuselage, wing and mounting structures.
· Design payload casings, enclosures and mounts with attention to weight, strength, thermal and ingress protection.
· Run pre-assembly analysis: fit, tolerance stack-up, CG and mass balance, and structural checks before build.
· Prepare production-ready CAD models, assemblies and engineering drawings with revision control.
Additive Manufacturing & Rapid Prototyping
· Take designs from CAD to print: orientation, supports, slicing, infill and process parameters for each material.
· Prototype and produce parts in PLA, PETG, ABS, ASA, Nylon, PC, TPU and carbon-fibre-filled polymers.
· Execute composite and continuous-fibre printing for load-bearing flight structures.
· Select materials and process routes against strength, stiffness, weight and environmental requirements.
Assembly, Integration & Validation
· Carry out carbon fibre assembly: bonding, joints, fasteners and airframe integration.
· Support flight and bench testing; convert test feedback into design improvements.
Printer Maintenance & Lab Operations
· Maintain, calibrate and troubleshoot FDM and composite printers: extruders, hotends, bed levelling, motion systems and firmware.
· Keep print quality consistent and downtime low; support lab SOPs and equipment usage discipline.
MUST-HAVE REQUIREMENTS
· 3–5 years in UAV or unmanned system design, with at least one platform taken to flight.
· Expert in 3D CAD (SolidWorks, Fusion 360, CATIA, Creo or equivalent); working knowledge of FEA or structural simulation.
· Hands-on experience across the full material range listed above, including carbon-fibre-filled polymers.
· Proven experience with composite and continuous-fibre printing.
· Strong command of pre-assembly analysis, payload casing design and carbon fibre assembly.
· Demonstrated ability to maintain, repair and troubleshoot 3D printers independently.
· Prior work on defence-grade projects, with comfort working under confidentiality requirements.
PREFERRED
· Innovative, original design work, such as weight-optimised or lightweight structures, modular or quick-swap designs, or novel printed solutions.
· Experience in design for additive manufacturing (DfAM) and lattice or topology optimisation.
HOW TO APPLY
Email directorops@enhansafe.com with:
· Detailed qualifications
· Work experience and key achievements (designs delivered, platforms flown, impact)
· Previous company relieving letter
· Salary slips
Subject line: "Application: UAV Design & Additive Manufacturing Engineer"

Work arrangement
No