Technical Lead - Mechanical Design

Location: Bangalore - Indraprastha, India

Thales is a global technology leader trusted by governments, institutions, and enterprises to tackle their most demanding challenges. From quantum applications and artificial intelligence to cybersecurity and 6G innovation, our solutions empower critical decisions rooted in human intelligence. Operating at the forefront of aerospace and space, cybersecurity and digital identity, we’re driven by a mission to build a future we can all trust.

Present in India since 1953, Thales is headquartered in Noida and has other operational offices and sites spread across Delhi, Gurugram, Bengaluru and Mumbai, among others. Over 2200 employees are working with Thales and its joint ventures in India. Since the beginning, Thales has been playing an essential role in India’s growth story by sharing its technologies and expertise in Defence, Aerospace and Cyber & Digital sectors. Thales has two engineering competence centres in India - one in Noida focused on Cyber & Digital business, while the one in Bengaluru focuses on hardware, software and systems engineering capabilities for both the civil and defence sectors, serving global needs. The Group has also established an MRO (Maintenance, Repair & Overhaul) facility in Gurugram to provide comprehensive avionics maintenance and repair services to Indian airlines and support the growth of the local aviation industry.

TECHNICAL LEAD - MECHANICAL DESIGN

PRIMARY PURPOSE OF THE ROLE

The person contributes to the hardware mechanical engineering activities required to design, develop and qualify an Interface test adaptor (ITA), Functional test Fixture for Electronics Unit Under Test (UUT) / Printed circuit board assembly, Special purpose machines, Precision tooling Systems (Assembly fixtures, etc.), Standard 19-inch rack systems, enclosures and/or hardware building blocks associated with it. Provide technical guidance to the team on topics relevant to mechanical design.

KEY RESPONSIBILITIES AND TASKS

• Collaborate (Local and Global) with multidisciplinary teams (Electronics, Industrialization, Manufacturing, Project management, Quality, Etc.) to design and/or realize the product.

• Understand customer needs and formalize the mechanical design requirements of the product / system.

• Detail necessary mechanical hardware component / sub-system requirements. Define the mechanical architecture compliant with product / system requirements.

• Support necessary estimation and planning of mechanical activities.

• Comply with applicable organization specific product design and development processes.

• Define the mechanical architecture of PCB & PCBA (Printed circuit board & Printed circuit board assembly) Define harness routing arrangements. Perform 3DCAD design of the mechanical architecture (Sheet metal and machined) and constituent components.

• Provide design solutions for thermal and vibration requirements. Perform appropriate material / finish process / component selection required for the design.

• Perform necessary design verification through any or all the following means

• Tolerance stackup analysis, Geometric dimensioning and tolerancing study

• Basic thermal and / or structural calculations

• Stability check of mechanical systems (Iso-statism and Hyper-statism)

• Material compliance analysis (REACH, RoHS, WEEE)

• Design for Environment (Temperature, vibration, EMI / EMC, etc.)

• Design for Manufacturability

• Design for Assembly

• Design for Testability

• Design for Maintainability

• Collaborate with Analysis engineer for various software-based analysis (Thermal / Structural / Vibration / shock etc.) of the design.

• Supply necessary design data and boundary conditions to perform analysis.

• Involve in technical discussion to validate the analysis results.

• Generate 2DCAD manufacturing drawings (with necessary GD&T or general tolerance controls), BOM and other documentations that constitute manufacturing data pack.

• Manage the design data (3D CAD, 2D CAD & documents) compliant with organization’s configuration management practices.

• Contribute to necessary project technical and milestone reviews (PDR: preliminary design review, CDR: Critical design review, etc.)

• Collaborate with external partners (Component suppliers, Test laboratories, other service providers, Etc.) for successful design, manufacturing and testing of the product.

• Participate in the integration and validation phases of designed system / product. Contribute to skill development and continuous improvement initiatives in the mechanical engineering discipline.                                

SKILLS REQUIRED

Essential

CAD tools:

• CATIA or Equivalent CAD Tool

• Capable of generating 3D CAD models of the following.

• Part – Sheet metal & machined types.

• Assembly – Separable & Inseparable. Capable of generating 2D Drawing and drafting in line with industry standards.

• Capable of generating BILL OF MATERIALS. Capable of defining and / or modifying 3D & 2D CAD templates.

• Good experience in best practices for CAD modeling and drafting.         

Mechanical Fundamentals:

• Simple bending / stiffness calculations.

• Tolerance stack up analysis, GD&T definitions. Component sizing / selection for dynamic assembly:

• Mechanical slides, guide pins, mechanical motion translation elements, Gripping and locking elements, etc.

• Assembly mating force, clamping force calculation. One-dimensional heat transfer calculation. Cooling Fan sizing calculation.

• Design for Manufacturing, Assembly, Testability and Maintainability concepts.

• Knowledge of general manufacturing processes and in separable assembly fabrication processes.

Industry Standards / Specifications: ANSI 14.1 or Equivalent ISO standard for GD&T definition. EIA-310: 19 Inch rack standard. [EIA: Electronics Industries Alliance]

Product design: Interface test adapter, Special purpose machines, Precision tooling Systems (Assembly fixtures, etc.),19 Inch rack system, Cabinets and Consoles.

Project Management: Activity estimation & Scheduling.

Desirable

Experience or exposure to the following.

CE certification of test bench or similar systems. Product environmental qualification

YEARS OF EXPERIENCE

8 to 15 years

EDUCATIONAL QUALIFICATION

Graduate/ Masters Degree in Engineering in Mechanical Design or Industrial Production

At Thales, we’re committed to fostering a workplace where respect, trust, collaboration, and passion drive everything we do. Here, you’ll feel empowered to bring your best self, thrive in a supportive culture, and love the work you do. Join us, and be part of a team reimagining technology to create solutions that truly make a difference – for a safer, greener, and more inclusive world.