Senior Component Design Engineer

ABOUT ASTROBASE SPACE TECHNOLOGIES

Astrobase is a pioneering spacetech startup founded by prominent Senior ISRO scientists and IIT Bombay alumni with over 20 years of experience in designing, manufacturing, testing and flying advanced Cryogenic Launch Vehicles. Driven by a vision to make India a Space tech powerhouse, we are developing innovative launch vehicles that will transform space exploration. At Astrobase, you’ll be part of a team creating history in the Indian space industry. Our goal is to become the first private space company from India to land on the moon economically.

ROLE OVERVIEW:

We are seeking an experienced Senior Component Design Engineer to lead the design, development, analysis, and qualification of high-performance mechanical components for cryogenic rocket engines, propulsion systems, and launch vehicles.

The role involves end-to-end ownership of critical fluid-control and mechanical components, including cryogenic valves, isolation and shutdown valves, control valves, pressure regulators, check valves, fluid connectors, and associated mechanisms operating under extreme pressure and temperature conditions.

The candidate will be responsible for translating system-level requirements into component designs, performing engineering calculations, selecting suitable materials and sealing technologies, supporting manufacturing and assembly, and leading component testing and qualification. The role requires close collaboration with propulsion, systems engineering, manufacturing, quality, procurement, and test teams to deliver safe, reliable, and flight-ready hardware.

KEY RESPONSIBILITIES

A. Component Design & Development

Design and development of mechanical components for cryogenic rocket engines, propulsion feed systems, and launch vehicles.

Design and optimize cryogenic and high-pressure components, including:

o Solenoid-operated valves (SOVs), shutdown valves, and isolation valves.

o Proportional and modulating control valves.

o Pressure regulators, check valves, and non-return valves.

o Fluid connectors, quick-disconnect couplings, and integrated valve assemblies.

o Pistons, actuators, springs, bellows, seals, and associated mechanisms.

Develop component architectures, concepts, detailed 3D models, 2D manufacturing drawings, and assembly drawings.

Establish component interfaces, installation envelopes, operating clearances, and functional requirements in coordination with system-level teams.

Optimize component mass, envelope, performance, reliability, manufacturability, and maintainability.

B. Engineering Analysis & Design Verification

Perform engineering calculations for pressure containment, structural strength, stress, deflection, buckling, fatigue, spring loads, actuation forces, and sealing performance.

Evaluate flow capacity, pressure drop, effective flow area, discharge coefficients, and valve operating characteristics.

Perform thermal and cryogenic assessments, including thermal contraction, differential expansion, material compatibility, and thermal effects on clearances and sealing.

Assess valve actuation forces, operating margins, response time, spring characteristics, and fail-safe functionality.

Support and interpret Finite Element Analysis (FEA), Computational Fluid Dynamics (CFD), and thermal simulations.

Conduct design trade studies, tolerance stack-up analysis, sensitivity studies, and failure-mode assessments.

Establish design margins and verify compliance with applicable design requirements and engineering standards.

C. Materials, Seals & Manufacturing

Select materials for cryogenic, high-pressure, oxidizer, fuel, and hot-gas applications based on mechanical properties, temperature limits, compatibility, and service conditions.

Evaluate metallic and non-metallic sealing solutions, including O-rings, spring-energized seals, polymer seats, metal seals, and bellows.

Specify materials, surface finishes, coatings, heat treatments, welding processes, and special manufacturing requirements.

Develop practical designs for precision machining, additive manufacturing, welding, brazing, and component assembly.

Apply Design for Manufacturing (DFM), Design for Assembly (DFA), and Design Failure Mode and Effects Analysis (DFMEA).

Resolve manufacturing deviations, dimensional non-conformances, assembly difficulties, and component performance issues.

D. Testing, Validation & Qualification

Prepare component verification plans, qualification requirements, acceptance criteria, and test procedures.

Support and review hydrostatic, pneumatic, proof-pressure, burst-pressure, leakage, functional, flow, and actuation tests as applicable.

Plan and support cryogenic thermal cycling, vibration, endurance, and environmental testing based on component requirements.

Analyze test data, identify failure mechanisms, conduct root-cause analysis, and implement corrective and preventive actions.

Ensure design modifications are supported by appropriate engineering assessments and verification testing.

Maintain traceability between requirements, design calculations, drawings, test results, and qualification records.

E. New Product Development & Project Execution

Own component development from concept generation through detailed design, prototype realization, qualification, and production release.

Develop engineering schedules, deliverables, design reviews, and technical risk mitigation plans.

Coordinate with propulsion systems, systems engineering, manufacturing, assembly, testing, quality, and procurement teams.

Evaluate technical feasibility, development risks, cost, lead time, and supplier capabilities.

Support procurement through technical specifications, supplier drawing reviews, material certification requirements, and inspection documentation.

Manage engineering changes, drawing revisions, configuration control, and release of approved design data.

Support production readiness, pilot builds, integration activities, and resolution of hardware issues during engine and launch vehicle testing.

F. Technical Documentation & Compliance

Prepare and maintain design reports, engineering calculations, material specifications, technical drawings, BOMs, DFMEAs, test procedures, and qualification reports.

Ensure compliance with applicable aerospace and engineering standards, including relevant ASME, NASA, ECSS, ISO, and company-specific requirements.

Participate in preliminary, critical, and manufacturing design reviews as applicable.

Maintain configuration control and complete engineering documentation throughout the component lifecycle.

Contribute to design standardization, lessons learned, reliability improvement, and continuous engineering development.

Required Skills & Experience

B.E./B.Tech. in Mechanical Engineering, Aerospace Engineering, or an equivalent engineering discipline.

8–12+ years of relevant experience in mechanical component design, aerospace hardware, propulsion systems, fluid-control equipment, or high-pressure systems.

Demonstrated experience in new product development and ownership of mechanical components from design through testing and qualification.

Strong hands-on experience with valves, regulators, actuators, fluid connectors, sealing systems, or similar precision-engineered hardware.

Practical knowledge of mechanical design calculations, material selection, tolerance analysis, and GD&T.

Experience with cryogenic fluids, high-pressure systems, low-temperature materials, or demanding aerospace operating environments.

Proficiency in 3D CAD software such as Creo, Siemens NX, CATIA, SolidWorks, or equivalent.

Working knowledge of FEA, CFD, thermal analysis, and engineering simulation methods.

Experience with manufacturing drawings, supplier coordination, inspection, assembly, and test support.

Strong technical documentation, problem-solving, and cross-functional communication sk