Principal Engineer – Composite Cylinders & Type IV Pressure Vessels

Company: DANTA INNOVATIONS PRIVATE LIMITED

Location: Bengaluru, Karnataka, India

Employment Type: Full-time | On-site

Experience: 8–15 years preferred

Company Description

DANTA INNOVATIONS develops advanced carbon fibre reinforced polymer (CFRP) composite solutions for defence, aerospace, and strategic industrial applications. The company focuses on lightweight, high-strength structures for demanding operational environments, including UAVs, missile systems, launch canisters, and mission-critical platforms.

DANTA is establishing advanced composite manufacturing capabilities spanning composite pressure vessels and aerospace structures. Our objective is to combine engineering excellence, advanced manufacturing technologies, and rigorous quality systems to deliver reliable, high-performance products.

Role Description

DANTA INNOVATIONS is seeking a highly experienced Principal Engineer – Composite Cylinders & Type IV Pressure Vessels with deep technical expertise in composite cylinder engineering, carbon fibre reinforcement, pressure vessel manufacturing, and product qualification.

This is a senior technical role responsible for leading the development and industrialisation of composite pressure vessels, from design and material selection through manufacturing process development, prototype production, testing, validation, and production readiness.

The ideal candidate will have hands-on experience with Type III and Type IV composite cylinders, polymer liners, carbon fibre composite overwraps, filament winding, resin systems, structural integrity, and pressure vessel testing. The candidate must understand the complete manufacturing lifecycle and be capable of independently solving complex engineering and production challenges.

Key Responsibilities1. Composite Cylinder Engineering

- Lead the engineering development of Type III and Type IV composite pressure vessels.
- Evaluate liner design, composite overwrap architecture, fibre orientation, load transfer, and structural performance.
- Support material selection, design for manufacturability, and manufacturing feasibility assessments.
- Investigate failure mechanisms, including fibre rupture, matrix cracking, delamination, liner deformation, and interface-related failures.
- Collaborate with design and analysis teams to improve product performance, durability, and manufacturability.

1. Filament Winding and Manufacturing

- Develop and optimise filament-winding processes for composite cylinders.
- Define winding patterns, fibre angles, winding sequences, tension parameters, and process controls.
- Establish procedures for liner preparation, surface treatment, winding, resin processing, curing, and finishing.
- Develop tooling, mandrel interfaces, fixtures, and manufacturing methods.
- Troubleshoot fibre misalignment, voids, resin-rich regions, delamination, and dimensional deviations.
- Conduct manufacturing trials and establish repeatable, documented process parameters.
- Improve manufacturing yield, material utilisation, productivity, and process consistency.

1. Composite Materials and Resin Systems

- Apply knowledge of carbon fibre reinforcement, epoxy resin systems, fibre–matrix interfaces, and composite material behaviour.
- Evaluate material compatibility,



mechanical properties, handling requirements, shelf life, and processing conditions.
- Investigate the effects of porosity, fibre waviness, resin distribution, and curing variations on vessel performance.
- Coordinate material qualification, supplier evaluations, and incoming inspection requirements.
- Establish material storage, handling, and traceability procedures.

1. Structural Analysis and Failure Investigation

- Work with structural analysts to evaluate pressure loading, stress distribution, strain behaviour, and composite failure mechanisms.
- Support assessments of burst strength, fatigue, cyclic loading, creep, and environmental durability.
- Correlate test results with design assumptions and manufacturing parameters.
- Lead root-cause investigations into failures, defects, and performance deviations.
- Recommend corrective actions supported by engineering analysis and experimental evidence.

1. Testing and Qualification

- Plan and coordinate hydrostatic, burst, cyclic pressure, and other applicable validation tests.
- Establish test plans, inspection requirements, and acceptance criteria in accordance with applicable standards.
- Support non-destructive testing (NDT), dimensional inspection, material characterisation, and failure analysis.
- Interpret test data and recommend design or process improvements.
- Support product qualification, certification documentation, and regulatory approvals.
- Ensure testing is conducted by appropriately equipped facilities using approved procedures and safety controls.

1. Manufacturing Setup and Industrialisation

- Lead the transition from prototype development to repeatable manufacturing and production readiness.
- Support equipment selection, machine commissioning, tooling development, and manufacturing trials.
- Develop standard operating procedures, process specifications, inspection plans, and production records.
- Establish critical process parameters and controls to improve repeatability and quality.
- Coordinate with suppliers of carbon fibre, resin systems, polymer liners, tooling, and manufacturing equipment.
- Train and mentor engineers and technicians and build internal technical capability.

1. Quality and Technical Documentation

- Maintain engineering drawings, material specifications, manufacturing procedures, and traceability records.
- Support applicable quality management systems and product-specific regulatory requirements.
- Develop process flow diagrams, control plans, risk assessments, and non-conformance investigation procedures.
- Ensure design and process changes are evaluated, documented, and validated.
- Maintain evidence supporting product verification, validation, and qualification.

Required Qualifications
- Bachelor's or master's degree in Mechanical Engineering, Aerospace Engineering, Materials Science, Polymer Engineering, or a related discipline.




- Substantial hands-on experience in composite cylinder engineering or pressure vessel manufacturing.
- Solid understanding of Type III and Type IV composite pressure vessel construction.
- Direct experience with polymer liners, carbon fibre composite overwraps, and associated manufacturing processes.
- Practical expertise in filament winding, including fibre orientation, winding patterns, tension control, and process optimisation.
- Strong understanding of composite materials, resin systems, curing, structural behaviour, and manufacturing defects.
- Experience with pressure vessel testing, failure investigation, process validation, or product qualification.
- Ability to translate engineering requirements into practical manufacturing procedures and measurable process controls.

Preferred Qualifications
- Experience developing Type IV cylinders from initial prototypes through testing and production readiness.
- Familiarity with applicable editions of ISO 11119, relevant gas cylinder regulations, and product-specific qualification requirements.
- Experience with carbon fibre and epoxy systems for high-pressure applications.
- Familiarity with CAD, finite element analysis, engineering drawings, and composite structural analysis.
- Knowledge of cyclic pressure testing, permeation assessment, environmental testing, and failure analysis.
- Experience establishing or scaling a composite pressure vessel manufacturing operation.
- Exposure to hydrogen storage, industrial gases, fire and safety, aerospace, or defence applications.

Expected Outcomes
- Establish a technically sound manufacturing and validation strategy for composite cylinders.
- Develop documented, repeatable manufacturing processes.
- Lead prototype development, manufacturing trials, and technical problem-solving.
- Coordinate testing and support product qualification with objective engineering evidence.
- Improve manufacturing quality, material utilisation, process consistency, and production readiness.
- Develop DANTA's internal technical capability in composite cylinder engineering and manufacturing.

Ideal Candidate Profile We are looking for a deep technical specialist who understands composite cylinders beyond general carbon fibre fabrication.

The ideal candidate has direct experience with Type IV pressure vessels and understands how liner behaviour, fibre architecture, resin properties, manufacturing parameters, and structural loading interact to determine cylinder performance and reliability.

Candidates should demonstrate practical engineering judgement, strong manufacturing knowledge, and the ability to investigate complex technical problems through calculations, testing, and evidence-based analysis.

Experience limited to general CFRP laminates, aerospace panels, or composite structures without relevant pressure vessel expertise will not be sufficient.

Technical priority: Direct Type IV composite pressure vessel experience is strongly preferred. Filament-winding expertise is required if the candidate will lead a filament-winding process.

Manufacturing technology: Candidates with Automated Fibre Placement (AFP) experience may also be considered where relevant to the intended manufacturing route. AFP and filament winding are distinct processes, and suitability must be demonstrated for the specific cylinder design and production requirements.

📌 Principal Engineer – Composite Cylinders & Type IV Pressure Vessels (Bengaluru)
🏢 DANTA INNOVATIONS
📍 Bengaluru