Head- Prototype Manufacturing process & Assembly Integration

Job Summary :

The Head of eVTOL Prototyping, Manufacturing Process & Assembly Integration will lead the end-to-end journey of transforming aircraft design into flight-ready prototypes and scalable production. This role owns prototype build strategy, manufacturing process development, tooling/fixture design, and full-aircraft assembly integration (structures, propulsion, avionics, electrical, and systems), ensuring the eVTOL platform moves efficiently from concept to certified, production-ready aircraft.

Key Responsibilities

1. Prototyping Leadership

• Own the strategy, planning, and execution of full-scale and sub-scale eVTOL prototype builds
  
• Translate design engineering outputs (CAD/PLM) into manufacturable prototype build packages
  
• Drive rapid iteration cycles between design, test, and manufacturing teams
  
  

2. Manufacturing Process Development

• Design and industrialize manufacturing processes for airframe structures and related subsystems
  
• Develop process plans, work instructions, routings, and standard operating procedures (SOPs)
  
• Lead Design for Manufacturing & Assembly (DFMA) reviews with design engineering
  
• Build the roadmap from low-rate initial production (LRIP) to full-rate production (FRP)
  
• Select and qualify manufacturing processes specifically composite layup/curing
  
  

3. Assembly Integration

• Own final assembly line (FAL) design, sequencing, and station-by-station build strategy
  
• Lead systems integration into the airframe.
  
• Define and implement jigs, fixtures, tooling, and assembly automation
  
• Ensure fit, form, and function compliance during integration; resolve build non-conformances
  
  

4. Quality, Safety & Compliance

• Ensure manufacturing and assembly processes comply with aerospace quality standards & DGCA regulations
  
• Implement inspection plans, first article inspection (FAI), and non-conformance/CAPA processes
  
  

5. Team & Cross-Functional Leadership

• Mentor and lead a multi-disciplinary team: manufacturing engineers, prototype technicians, assembly integration engineers, tooling designers
  
• Partner closely with Design Engineering, Systems Engineering, Test & Flight Operations, Supply Chain, and Quality teams
  
• Manage relationships with external vendors, fabrication partners, and suppliers
  
• Own budgeting, resource planning, and program timelines for prototyping and assembly functions
  
  

6. Continuous Improvement & Scale-up

• Drive lean manufacturing, 5S, and Kaizen practices on the shop floor
  
• Develop the strategy for scaling from prototype to series production, including facility/line planning
  
• Evaluate and implement automation, digital manufacturing (MES/PLM integration), and Industry 4.0 tools
  

Experience Required

12–18+ years in aerospace/aircraft manufacturing, prototyping, and assembly integration, with at least 4–5 years in a leadership role. Prior eVTOL, UAV, helicopter, or aircraft OEM experience strongly preferred.

Education

• Bachelor's/Master's degree in Aerospace, Mechanical, Manufacturing, or Production Engineering
  
• Additional certifications in Lean Manufacturing, Six Sigma, or Aerospace Quality Systems (AS9100) preferred
  
  

Requirements

Deep hands-on knowledge of aircraft structures, composites, and metallic assembly techniques

Experience with manufacturing engineering tools (CAD/CAM, PLM, MES, Six Sigma/Lean)

Proven track record of taking a program from prototype to production

Strong leadership, cross-functional collaboration, and stakeholder management

Excellent problem-solving skills in a fast-paced, first-of-kind product environment

Familiarity with certification requirements for eVTOL/UAM aircraft is a strong plus