Job Title: Senior R&D; Thermoplastic Manufacturing Engineer (Startup)

Experience: 2–5 years industry experience (or PhD + relevant research)
Education: Minimum M.S.(PhD strongly preferred)
Department: Advanced Manufacturing / R&D;
Reporting To: CTO / VP Engineering / Founder

Position Summary

We are an early-stage aerospace composites startup developing next-generation thermoplastic composite structures for civil and defence applications. We seek a highly capable R&D; engineer who can convert cutting-edge materials and manufacturing concepts into scalable production-ready processes.

This role requires both deep technical knowledge and strong hands-on execution. The candidate must be comfortable working in an unstructured startup environment, moving between laboratory experimentation, process development, tooling design, factory setup, and customer demonstrations.

Key Responsibilities

- Lead development of novel thermoplastic composite manufacturing processes from concept to pilot production.

- Build and optimize manufacturing methods including:

- Thermoforming

- Compression molding

- Stamp forming

- Automated layup

- Induction / resistance welding

- Over-molding and hybrid molding

- Design and execute R&D; experiments using DOE and statistical methods.

- Establish process windows for temperature, pressure, dwell, and cooling cycles.

- Develop methods to reduce defects such as porosity, wrinkles,



incomplete consolidation, and weld failures.

- Work directly with founders to define technology roadmap and IP strategy.

- Evaluate new materials, suppliers, and equipment.

- Support prototype builds and customer demonstrations.

- Help build internal manufacturing labs, process documentation, and SOPs.

- Contribute to patent disclosures, technical publications, and proposal writing.

Requirements

Required Qualifications

- M.S. minimum; PhD preferred in engineering or materials science.

- 2–5 years of relevant industrial experience, OR PhD with strong applied research.

- Strong knowledge of thermoplastic composites and polymer processing.

- Hands-on experience with high-performance polymers such as PEEK, PEKK, PPS, and PEI.

- Familiarity with composite testing, microscopy, and failure analysis.

- Robust analytical and experimental mindset.

Ideal Startup Candidate Traits

- Builder mentality; comfortable creating systems from scratch

- Highly hands-on in lab/shop environments

- Comfortable with ambiguity and rapid iteration

- Strong ownership mindset

- Can operate independently with minimal supervision

- Strong communication with customers, investors, and technical partners

- Demonstrated ability to build something from zero (lab, process, prototype, tooling, or pilot line)

📌 Senior R&D Thermoplastic Manufacturing Engineer (Startup) (Bengaluru)
🏢 AeroDef Nexus Group
📍 Bengaluru