Mechanical Design Engineer (Electric Powertrain)

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.