Senior Battery Pack Prototype Manufacturing Engineer (m/f/d)

  • Full-time
  • Site: Bruchsal HQ
  • Department: Engineering & Production

Company Description

We at Volocopter are pioneers in the development of electrical air taxis that take off and land vertically (eVTOLs). We bring Urban Air Mobility to life, by establishing air taxis in addition to current transportation options in megacities globally. Our aim is to offer affordable on-demand air taxi services and save people time by flying them safely to their destination. In 2011 we performed the first-ever piloted flight of a purely electrical multicopter and have since showcased numerous public flights with our full-scale Volocopter (www.volocopter.com).

Job Description

As a Senior Battery-pack Prototype Manufacturing Engineer, you will develop reliable manufacturing methods to ensure the end product meets the design intent for each component of the battery system of the Volocopter. You work closely with design engineers and testing and quality teams. You will define manufacturing/prototyping methods and develop reliable work instructions that ensure high quality levels for the battery systems’ components which follow the latest industry best practices and aviation certification standards.

Your Tasks:

  • Help create high-quality prototypes and representative units for design development and certification testing.
  • Assist the design team and propose manufacturing methods that match the available timeframe and design intent
  • Setup a prototyping workshop from scratch and define production/prototyping layouts, define parts routers as to track components status in the assembly line
  • Define, select and assist in the procurement and setup activities of equipment for cell incoming inspection and cell welding
  • Help design, source, and manufacture jigs and fixtures to enhance flying part manufacturability or assemblability.
  • Ensure the availability of materials and tools for prototype production
  • Define installation and assembly requirements
  • Create work instructions for part manufacturing and/or assembly
  • Define quality gates throughout the prototyping line
  • Raise NCRs, Concessions, Change Requests, Part releases, etc.
  • Establish KABAN system to secure efficient and consistent parts flow.
  • Train technicians to execute jobs based on the established work instructions and ensuring the highest aerospace standards.
  • Evaluate stack-up of COTS and resulted manufactured components as to provide input to design engineers.
  • Help to maintain a correct M-BOM, part supply, supplier relationship and assurance system.

Qualifications

  • Hand-on, creative and solution-oriented way of working
  • Ability to demonstrate accurate prototyping methods to the proposed design solutions
  • Experience in composite structures development (Mold creation, layup, resin infusion, vacuum and autoclave systems, etc)
  • Knowledge in Battery Systems, their components and related design and development activities
  • Experience in setting up a battery cell welding prototype/production line
  • Qualified to work in a HV environment
  • Experience with production quality management standards (at least ISO9001), systems and tools
  • Masters Degree in the area of mechanical engineering, electrical engineering, aeronautic manufacturing/prototyping design or equivalent
  • Experienced in using CAD software and Product Lifecycle platform
  • Good writing and speaking skills in English

Good to have:

  • Experience in fire resistant materials and processes
  • Experience in fastening systems
  • Experience in managing technical teams
  • Experience in aerospace manufacturing environments, knowledge and expertise of Part 21J and EASA DOA functions
  • Experience in aerospace quality standards (AS9100, ISO 8788)

Please submit your resume in English only. 

Additional Information

Our Offer:

  • Fast-growing high tech company with a supreme network of investors and partners
  • Ability to contribute directly to the future of aviation
  • The chance to build up new things/projects from scratch
  • Personal accountability, growth and learning opportunities, based on your personal strengths
  • An inspiring working environment with modern workspaces, flexible work time, short lines of communication, flat structures, great team spirit

Our differences make us stronger. At Volocopter, we stand for inclusion for all. We believe that diversity drives innovation and in building a culture where difference is valued. Come and join us on our journey!

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