Head- Prototype Manufacturing process

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.

Responsibilities

• 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
• 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
• 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
• 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
• 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
• 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

Requirements

• 12+ 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.
• 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

Education

• Bachelors/Masters degree in Aerospace, Mechanical, Manufacturing, or Production Engineering

Qualifications

• Additional certifications in Lean Manufacturing, Six Sigma, or Aerospace Quality Systems (AS9100) preferred

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