Lead Mechanical Design Engineer

Role Summary

The incumbent will lead the mechanical design and development of advanced Weapon Upgradation Kits and Electro-Optical Systems, including thermal imaging, night vision, and day optics. The role is responsible for the complete product development lifecyclefrom concept to production and lifecycle management—with a strong focus on innovation, quality, cost optimization, and timely delivery. The position also provides technical leadership and mentors the mechanical design team.

Key Responsibilities

1. Leadership & Team Development

• Lead, mentor, and develop the mechanical design team.
• Drive adherence to engineering standards, design methodologies, and best practices.
• Manage team performance and support technical and professional development.

2. Mechanical Design & Product Development

• Own the complete mechanical design lifecycle from concept through production release.
• Develop project plans, monitor progress, and provide regular management updates.
• Drive innovation through advanced materials, manufacturing technologies, and cost-effective design solutions.
• Establish strategic direction for mechanical design capability and innovation.
• Ensure protection of design data and intellectual property in line with company and defense cybersecurity requirements.

3. Design Execution

• Design and review mechanical components and assemblies using CAD tools (SolidWorks,CATIA, Creo, NX).
• Develop weapon accessories, electro-optical assemblies, and related mechanical systems.
• Design for manufacturability across machining, casting, injection molding, sheet metal, and additive manufacturing.
• Perform engineering analyses including thermal, structural, fit, form, ingress protection (IP), impact protection (IK), and FEA using ANSYS or Abaqus.
• Prepare engineering drawings, BOMs, assembly instructions, and design documentation.

4. Quality, Validation & Compliance

• Apply GD&T principles (ASME Y14.5/ISO) for manufacturable and interchangeable designs.
• Perform tolerance stack-up analysis, FAI, CMM validation, and PPAP reviews.
• Conduct DFMEA, PFMEA, and DVP&R activities.
• Ensure compliance with applicable defense, environmental, and industry standards including MIL-STD, RoHS, and REACH.

5. Project & Vendor Management

• Coordinate prototype development and production with suppliers and manufacturing partners.
• Work closely with Electrical, Electronics, Firmware, Manufacturing, QA, Engineering, and SCM teams.
• Interface with OEMs regarding technical documentation, certifications, authorizations, and tender queries.

6. Testing & Product Improvement

• Support product testing, field trials, and user evaluations.
• Troubleshoot design issues through development and production.
• Conduct root cause analysis and implement corrective actions.
• Improve manufacturability using DFMA principles.

7. Documentation & Technical Support

• Maintain accurate BOMs, SAP records, and engineering documentation.
• Manage product datasheets, specifications, and design records.
• Support product demonstrations, exhibitions, and customer interactions.
• Modify existing products based on customer or technical requirements.
• Conduct technical studies on optical, thermal imaging, and night vision systems.

Job Specifications

Education

• Bachelor's or Master's Degree in Mechanical Engineering or an equivalent discipline.

Experience

• 8–15 years of mechanical design experience in precision electro-optical or defense systems.
• Minimum 3 years in a technical lead or senior engineering role.

Technical Competencies

• Proficiency in SolidWorks, Creo, CATIA, or NX.
• Strong knowledge of GD&T (ASME Y14.5/ISO), tolerance analysis, and inspection planning.
• Experience with ANSYS or Abaqus for structural and thermal analysis.
• Expertise in machining, casting, sheet metal fabrication, plastic injection molding, and additive manufacturing.
• Experience with PLM and SAP/ERP systems.
• Strong understanding of DFM, DFA, and rapid prototyping.

Preferred Skills

• Leadership, communication, and stakeholder management skills.
• Ability to manage multiple projects and meet challenging timelines.
• Familiarity with ISO and military standards (MIL-STD-810, MIL-STD-883, JS 55555).
• Knowledge of weapon systems, thermal imaging, and night vision devices.
• Experience working with Government laboratories, OEMs, defense integrators, and certification agencies.