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A strong aerospace ecosystem needs skilled SMEs and talent:
Articles- Jul 27,26
In an interview with Ashlin Rajan, Bharat Bhushan Nagpal, CEO, Merlinhawk Composites & Engineering Pvt Ltd, discusses advanced manufacturing and India’s growing aerospace capabilities
How has Merlinhawk Aerospace evolved into advanced aerospace manufacturing?
Merlinhawk’s journey has a long-term commitment towards building reliable engineering capabilities in the aerospace and defence sector. We started over 40 years ago with avionics, microwave systems, embedded electronics, cable harnesses and other mission-critical solutions where precision and consistency are important.
Over the years, working closely with Indian defence programmes and global aerospace companies has given us valuable insights into international manufacturing standards and customer expectations. As the industry evolved, we felt it was important to move beyond systems integration and strengthen our manufacturing capabilities as well.
Our entry into advanced composites is a natural extension of that journey. Today, we are combining design, engineering, and advanced manufacturing to build products that meet global aerospace standards while contributing meaningfully to India's growing aerospace ecosystem.
What strategic role will the Shoolagiri composites facility play?
The Shoolagiri facility is a major milestone in Merlinhawk’s long-term growth. With aerospace platforms getting more efficient and increasingly dependent on advanced materials, composites have become a part of modern aircraft and defence systems. This facility allows us to produce these essential components in India itself, following internationally accepted processes and quality standards.
In many ways, this aligns with the broader objective of Atmanirbhar Bharat. Building indigenous capability in advanced composites is not only about reducing import dependence, it is about creating the technological depth and manufacturing confidence required for India to become a long-term contributor to the global aerospace and defence industry.
The key is that we have engineering, manufacturing, and quality assurance all under one roof, giving us more control over every step of the production. That level of integration is critical in aerospace where consistency and reliability are as important as innovation.
Additionally, the facility positions us to support Indian defence programmes and international customers with advanced manufacturing capabilities meeting stringent global requirements.
How is the Vega Composites partnership enabling technology transfer and manufacturing excellence?
Our partnership with Vega Composites has been built on the principle of developing capabilities, not simply setting up production. We see technology transfer as the sharing of knowledge, processes, and engineering expertise that can be sustained and further developed in India. T
hrough this collaboration, our teams are gaining hands-on experience with the advanced composite manufacturing, specialised tooling, quality systems and production methods developed over many years in the European aerospace industry.
Vega also brings significant expertise in composites, and Merlinhawk has decades of experience in Indian aerospace engineering and manufacturing. Together we are creating a capability that lives up to global expectations even as we strengthen India’s position as a trusted partner in the international aerospace supply chain.
Which advanced technologies and processes have been integrated into the facility?
Advanced composite manufacturing is a highly process-driven discipline where consistency is as important as technology itself. At our Shoolagiri facility, every stage of production has been designed to meet the quality expectations of the aerospace industry. We have integrated temperature-controlled storage for composite materials, ISO-class clean room environments for layup operations, automated precision cutting systems, vacuum bagging processes, autoclave curing, and five-axis CNC machining for high-accuracy finishing.
Each process is supported by rigorous quality checks and traceability, which are fundamental requirements in aerospace manufacturing. Beyond the equipment itself, equal emphasis has been placed on process discipline, documentation, and workforce training.
Together, these capabilities enable us to manufacture complex composite structures with the precision and repeatability that aerospace and defence applications demand.
How is Merlinhawk moving towards design-led engineering and manufacturing?
The aerospace industry is increasingly looking for partners who can contribute engineering expertise rather than only manufacturing capacity. That is the direction we have consciously chosen for Merlinhawk. Our experience in avionics, systems engineering, and mission-critical technologies has given us a strong engineering foundation.
With the addition of advanced composites, we are extending that capability into product design, materials engineering, manufacturing, and lifecycle support. This allows us to engage much earlier in the product development process and work alongside customers to optimise performance, manufacturability, and quality.
Our goal is not simply to produce components to specification, but to become a trusted engineering and manufacturing partner that can deliver integrated solutions for increasingly complex aerospace and defence programmes.
What opportunities will the facility create for Indian SMEs and suppliers?
No aerospace company operates in isolation. A strong manufacturing ecosystem depends on capable suppliers, specialised SMEs, and a skilled workforce working together. We see this facility as a catalyst for strengthening that ecosystem.
As production expands, there will be opportunities for Indian suppliers to participate in specialised tooling, machining, materials handling, testing, logistics, and other supporting activities that are essential to aerospace manufacturing.
More importantly, they will have the opportunity to align themselves with global quality systems and manufacturing standards, which enhances their competitiveness beyond a single project or customer.
We also believe the facility will contribute to the continued development of the Tamil Nadu Defence Corridor by creating skilled employment and encouraging greater collaboration between industry, academia, and technology partners.
What is Merlinhawk’s roadmap for talent, technology and global supply-chain integration?
Building a future aerospace organisation requires continuous investment in technology, people and long-term partnerships. We are building our roadmap to reinforce all three. We will keep growing our capabilities in advanced materials, precision manufacturing and engineering, while also ensuring that our processes remain aligned with evolving aerospace standards globally. The development of skilled talent is just as important.
Composite manufacturing requires specialised expertise, and we are investing in structured training programs, knowledge sharing with our international partners and continuous technical development for our engineers and technicians.
Our aim is to be a trusted long-term partner in global aerospace supply chains by consistently delivering quality, engineering excellence and capabilities that support India’s strategic priorities and the evolving needs of the international aerospace industry.
Bharat Bhushan Nagpal
Merlinhawk Composites & Engineering
Merlinhawk Aerospace
aerospace manufacturing
advanced composites
Shoolagiri facility
aerospace engineering
technology transfer
Indian aerospace supply chain
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