Design, develop, and validate jigs, fixtures, templates, and assembly tools for aviation helmets. The role requires a deep understanding of sub-assembly’s helmet shells, dual-visor systems, NVG shrouds, liner/pad sets, retention hardware, and communications/oxygen interfaces—and of correct fitment practices to deliver accurate, consistent, repeatable assembly across size variants.

Key Responsibilities

1) Design & Development

- Design production-ready templates, jigs, fixtures, and tooling that ensure accurate, effective component assembly.
- Engineer for repeatability and poka-yoke to minimize operator error.
- Optimize for ease of use, durability, serviceability, and non-marring contact with optical/painted surfaces.

2) Process & Fitment Optimization

- Standardize assembly procedures to achieve consistent fit, alignment, and quality (visor tracks, NVG mount location, rail alignment, earcup seal).
- Define and standardize hardware types and correct fitment/torque practices.
- Reduce cycle time and improve operator ergonomics and changeover (SMED mindset).

3) Collaboration & Integration

- Can Handle the team of 5-8 Members including engineers, technicians etc.
- Work closely with team to align tooling with product requirements, tolerances, and datum strategies.
- Coordinate with Procurement/Vendors for material selection, fabrication, and qualification of tools.




- Interface with QA/Production for pilot builds and ramp support.

Testing & Validation

- Support and participate in helmet qualification tests, including:
1. Impact attenuation testing on instrumented headforms.
2. Penetration resistance verification under striker impact.
3. Wind-blast testing in high-speed airflow conditions (with/without NVG, visor up/down).
4. Visor mechanical tests (impact, abrasion, scratch, chemical, fog resistance).
5. Visor optical tests (transmittance, haze, distortion, prismatic imbalance).

- Collaborate with test labs (e.g., NAL, TBRL) and internal QA teams to ensure compliance with CEMILAC/DGAQA standards.
- Document all test results, prepare QTP/QTR, and drive corrective actions.

5) Documentation & Continuous Improvement

- Prepare CAD models (SolidWorks), 2D drawings, work instructions/SOPs, check sheets, and maintenance manuals for all tooling.
- Drive continuous improvement using in-process quality data and operator feedback; maintain revision control and traceability.

6) Safety & Compliance (Heli-Specific)

- Design tools/processes that respect aviation expectations
- Maintain shell integrity use proper drill bushings, datum schemes, and avoid over-constraint of composite shells.
- Support weight & balance/CG checks for NVG and non-NVG configurations.

📌 Aviation Helmet Engineer (Kanpur)
🏢 MKU
📍 Kanpur