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

📌 Head- Prototype Manufacturing process & Assembly Integration (Chengalpattu)
🏢 Ubifly Technologies
📍 Chengalpattu