Head of R&D – Composites (UAV)

Head of R&D – Composites (UAV) 📍 Thanjavur | Full-Time We are looking for a highly experienced Head of R&D – Composites to serve as the organisation’s technical authority for composite design and manufacturing. This is a senior role that will work closely with the Product Development Team , providing expert guidance on composite airframe design, structural optimisation, mould/tooling strategy, material selection, and manufacturability, while taking complete ownership of the Composite Fabrication Team and processes . Key Responsibilities Advise the Product Development Team on composite airframe design, structural concepts, material selection, laminate design, and manufacturability . Review and optimise UAV wings, fuselage, control surfaces, fairings, and other composite structures for weight, strength, stiffness, and production feasibility. Provide technical leadership for mould and tooling design , including mould architecture, master patterns, bonding/assembly fixtures, and production tooling. Lead the complete Composite Fabrication Team , from prototype development through production. Establish and optimise prepreg layup, vacuum bagging, oven/autoclave curing, wet layup, bonding, trimming, finishing, and assembly processes . Define laminate schedules, ply orientation, core materials, adhesives, curing cycles, and composite manufacturing standards. Lead composite prototype development, process trials, structural testing, failure analysis, and continuous improvement. Establish SOPs, quality controls, inspection criteria, process documentation, and workmanship standards . Develop the composite team's capabilities, infrastructure, equipment, and production processes as UAV programs scale. Work closely with Product Development, Tooling, Quality, Manufacturing, and Flight Test teams to resolve airframe and composite-related challenges. Requirements 6+ years of hands-on experience in advanced composite design and manufacturing, preferably in UAV or aerospace applications. Deep expertise in prepreg carbon fibre, GFRP, sandwich structures, honeycomb/foam cores, adhesives, and composite tooling . Strong experience in UAV/aerospace airframe design optimisation and composite structural manufacturing . Proven experience designing and developing composite moulds and production tooling . Strong understanding of laminate design, structural bonding, curing processes, GD&T, tolerances, and composite inspection/testing . Demonstrated experience leading composite fabrication teams and establishing production processes . Strong ability to review engineering designs and provide practical recommendations based on structural performance and manufacturability . Ideal Candidate We are looking for someone who has personally taken composite aerospace/UAV structures from design review → mould/tooling development → prototype fabrication → testing → design optimisation → production and can act as the company's senior technical mentor for all composite-related engineering and manufacturing decisions.