Composite Manufacturing & Aircraft Integration- Lead Engineer

Job Summary

• As the Lead Engineer, the candidate will lead the manufacturing process development, tool manufacturing, and final structural integration of advanced composite parts into flight-qualified aircraft structures. This role requires a skilled individual with a strong understanding of composite materials, manufacturing processes, and assembly techniques. The candidate will work with a team of engineers and technicians to produce high-quality composite parts that meet stringent specifications as per certification requirements. The candidate has to work closely with the cross functional teams & support in the DFM process.

Required Qualifications:

• Education: Bachelor’s or Master’s degree in Aerospace, Mechanical, Materials, or Manufacturing Engineering.
• Experience: 7 to 10 years of hands-on experience in the aerospace composite manufacturing & Assembly process, with at least 1–2 years in a senior or lead capacity.

Key responsibilities:

• Manufacturing Process Development: Establish and optimize production architectures for large composite structures.
• Aircraft & Systems Integration: Oversee the final structural assembly and integration of mechanical systems, avionics, and wire harness into composite airframes, ensuring precise fits and tolerances.
• Design for Manufacturing & Assembly (DFM/DFA): Work closely with structural design teams early in the development cycle to ensure complex composite parts are inherently manufacturable, scalable, and cost-effective.
• Risk & Defect Management: Conduct Process Failure Mode and Effects Analysis (PFMEA). Troubleshoot complex manufacturing defects through structured root cause analysis (RCCA) and implement corrective actions.
• Documentation & Quality Compliance: Ensure manufacturing and assembly is done as per released documents adhering to aerospace standards & certification requirements.
• Team Leadership: Provide technical guidance, prioritization, and mentorship to a team of manufacturing, integration engineers and technicians.

Additional Skills:

• Quality Control: Strong attention to detail and commitment to quality workmanship.
• Problem Solving: Ability to identify and resolve manufacturing and assembly issues.
• Teamwork: Ability to work effectively as part of a collaborative team.
• Safety Consciousness: Adherence to safety protocols and procedures.
• Strong familiarity with GD&T (Geometric Dimensioning and Tolerancing), assembly fits, and metrology.

Job Location: The manufacturing facility is located at the prestigious IIT Madras Thaiyur Campus, Thaiyur Road, Senganamal, 603103. This location offers a vibrant and intellectually stimulating environment with access to cutting-edge research and development.