Senior Electromechanical Engineer
Confirmed on the employer's own hiring board on Oct 23, 2026. First seen by Alion on Sep 30, 2026.
Senior Electromechanical Engineer
Department: TEC Electrical & Battery
Experience Level: 6-9 Years
Location: Chennai, India
Position Type: Full-Time / New Role
About the Role
As a Senior Electromechanical Engineer, you will own the physical packaging, structural housing, and mechanical integration of our high-voltage battery modules and electrical powertrain systems into the eVTOL airframe. This is a highly cross-functional role bridging electrical power architectures and structural mechanics. You will transform complex electrical systems into flight-ready, structural assemblies, ensuring optimal thermal paths, structural integrity under high-g flight envelopes, and strict optimization for aircraft weight and mass balance.
What You Will Do
Enclosure & Packaging Design: Design robust, lightweight, and crash-worthy enclosures, mounts, and structural brackets for high-voltage battery packs, power electronics, power distribution units (PDUs), and inverter modules.
Advanced 3D Modeling: Utilize CATIA V5/V6 (3DEXPERIENCE) to build complex electromechanical assemblies, leveraging surface modeling for aerodynamic integration and airframe routing constraints.
Precision Engineering & GD&T: Apply rigorous Geometric Dimensioning & Tolerancing (GD&T) principles per ASME Y14.5 to ensure flawless fitments between machined enclosures, sheet metal shields, and composite airframe interfaces. Perform detailed tolerance stack-up analyses.
Design for Excellence (DfM / DfA / DfT): Inject Design for Manufacturing, Assembly, and Testing principles early into the development lifecycle to drive down component counts, minimize assembly cycle times, and simplify shop-floor production.
Material & Structural Selection: Select and qualify aerospace-grade alloys, high-performance plastics, structural adhesives, and advanced Thermal Interface Materials (TIMs) to maximize heat dissipation while ensuring structural safety.
HV Isolation Engineering: Coordinate closely with the electrical team to design mechanical clearances that respect strict creepage and clearance boundaries for high-voltage components.
HV Box Design: Assemblies involving Contactors, Busbars, Fuses, Pyrofuses, Manual Service Disconnect switches, etc.
What We Are Looking For (Must-Haves)
Experience : 6 to 9 years of dedicated mechanical or electromechanical packaging experience within the aerospace, electric vehicle (powertrain/battery), or high-reliability defense sectors.
CAD Mastery : Advanced, hands-on expertise in CATIA V5 / V6 (3DEXPERIENCE), specifically utilizing advanced assembly design, sheet metal workbenches, and mechanical part design.
Drafting & Stack-up Depth : Expert-level knowledge of GD&T and a proven track record of resolving complex multi-part tolerance stack-ups.
Manufacturing Knowledge : Direct experience designing parts optimized for CNC machining, sheet metal fabrication, structural bonding, and lightweight casting or molding.
Exposure to Electrical System Design constraints : Excellent understanding & design capability on - Ingress protections, Water proof / Dust proof designs, Good understanding of clearance & creepage distances, Switches Panel creation, Electrical sub-assemblies.
Certification / Compliance : Experience in prototyping as well as production planning kind of environment. Ideal candidates should have designed, developed & taken at least one such development through full certification through the likes of DGCA / CEMILAC / ARAI.
Preferred Skills (Good-to-Have)
Working knowledge of Mechanical Shape Design within CATIA for complex surface modeling.
Experience packaging high-voltage systems (upto 800VDC) and managing mechanical safety barriers against electric shock or thermal runaway.
Familiarity with environmental testing standards like RTCA DO-160 (specifically regarding vibration, shock, and thermal profiles).
Excellent understanding of electrical system design, electrical properties of materials, dielectric strength, creepage & clearances, thermal properties of materials.
Good understanding of - Grounding / bonding required for electrical components, Enclosure design & fabrication for electrical systems, Design for Ingress Protections.
Exposure to material selection for electrical products.