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The Role
Leads eVTOL prototype manufacturing, process development, tooling, and full-aircraft assembly integration from design through production scale-up. Owns prototype build strategy, manufacturing documentation, DFMA, final assembly line planning, systems integration, quality compliance, FAI, non-conformance resolution, team leadership, supplier coordination, budgeting, and lean or digital manufacturing initiatives. The role requires deep aerospace structures, composites, metallic assembly, and prototype-to-production experience.
Summary Generated by Built In
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.
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
- 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
- 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
- Ensure manufacturing and assembly processes comply with aerospace quality standards & DGCA regulations
- Implement inspection plans, first article inspection (FAI), and non-conformance/CAPA processes
- 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
- 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
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.
- 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
Skills Required
- 12–18+ years of experience in aerospace or aircraft manufacturing, prototyping, and assembly integration
- At least 4–5 years in a leadership role
- Bachelor’s or master’s degree in Aerospace, Mechanical, Manufacturing, or Production Engineering
- Deep hands-on knowledge of aircraft structures, composites, and metallic assembly techniques
- Experience with CAD/CAM, PLM, MES, Six Sigma, and Lean manufacturing tools
- 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
- Prior eVTOL, UAV, helicopter, or aircraft OEM experience
- Certification in Lean Manufacturing, Six Sigma, or aerospace quality systems such as AS9100
- Familiarity with eVTOL or UAM aircraft certification requirements
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The Company
What We Do
We're developing India’s 1st flying electric taxi for up to 10x faster intra-city commute and cargo transport. Incubated at IIT Madras, Chennai since 2019, The ePlane Company was founded by Professor Satya Chakravarthy with a vision to make flying ubiquitous. As an Urban Air Mobility (UAM) startup, we aim to alleviate on-road traffic congestion in cities worldwide by offering safe, sustainable and affordable flying experiences through our flagship product, The ePlane e200.
