Key Responsibilities and Required Skills for Kite Maker

🎯 Role Definition

We are seeking a hands-on Kite Maker — a craft-focused production specialist who designs, fabricates, and tests high-quality kites for recreational, competition and display use. The ideal candidate combines practical sewing and composite assembly skills with an understanding of aerodynamics, materials science (ripstop nylon, Dacron, carbon fiber, bamboo), and pattern design. This role supports prototype development, quality assurance, small-batch manufacturing, repairs and customer-facing custom builds.

📈 Career Progression

Typical Career Path

Entry Point From:

Textile or sailmaker apprentice transitioning to specialty product fabrication
Industrial sewing operator, upholsterer, or canvas technician with experience in technical fabrics
Woodworker, CNC operator or composite assembler with an interest in kite/aero products

Advancement To:

Senior Kite Designer / Lead Fabricator
Production Manager — small-batch or artisanal outdoor gear
Product Development Engineer or Industrial Designer for wind-sports equipment
Founder / Owner of specialized kite brand or repair shop

Lateral Moves:

Sailmaker or small-boat canvas specialist
Outdoor product assembler (paragliding, tents, sails)
Textile pattern maker or prototyping technician

Core Responsibilities

Primary Functions

Design, draft and refine kite patterns using both hand-drafting techniques and CAD tools (e.g., Rhino, SolidWorks, Inkscape), ensuring accurate panel layouts, seam allowances and load paths for stable flight performance.
Select and source appropriate materials (ripstop nylon, polyester sailcloth, Dacron, mylar, carbon fiber spars, bamboo, bridles, line) and maintain an up-to-date material specification log for each product line and custom order.
Cut fabric and panels with precision using manual, semi-automated and CNC cutting methods, applying nesting strategies to optimize yield and reduce waste.
Operate industrial sewing machines, overlockers and hand-stitching techniques to assemble sails with reinforced seams, edge tapes, battens pockets and attachment points to manufacturer tolerances.
Shape, assemble and finish spars and frames (carbon fiber, fiberglass, bamboo), including bonding, epoxy layup, heat-shrinking, sanding and protective coatings to meet strength and flex specifications.
Build prototypes from concept through flight-ready sample, iterate design based on wind testing and feedback, and document version-controlled changes to patterns and BOMs (bills of materials).
Conduct controlled wind-tunnel or field wind testing, record flight data (stability, pull, lift, turning behavior), analyze results and implement design improvements for performance and safety.
Perform detailed quality inspections at multiple stages of production (incoming materials, in-process, final QC), using checklists to verify seam integrity, stitch count, reinforcement placement, and dimensional accuracy.
Repair and restore customer kites — evaluating damage, recommending durable fixes, executing structural repairs and communicating repair quotes and turnaround times to customers.
Prepare and maintain accurate production records, work orders and build sheets; track time per unit for cost analysis and continuous improvement.
Ensure all products comply with relevant safety standards and labeling requirements (load ratings, age recommendations, usage instructions), and support product safety documentation.
Finish and package completed kites with protective packing, assembly instructions, bridles pre-tied when required, and SKU labeling for shipping and retail presentation.
Train and mentor junior fabricators and apprentices on pattern reading, sewing techniques, composite handling and shop safety, establishing standard operating procedures (SOPs) for consistency.
Troubleshoot manufacturing issues (machine calibration, material defects, fit problems), implement corrective actions and update process documentation to prevent recurrence.
Collaborate with design, marketing and sales teams to translate customer feedback into manufacturable product improvements and limited-edition releases.
Maintain tooling, jigs, sewing machines and composite workspaces — schedule preventive maintenance, reorder expendables and keep the workshop organized for efficient workflow.
Estimate labor and material costs for custom commissions and production runs, prepare quotes for customers and support pricing strategy for small-batch or made-to-order models.
Implement sustainability and waste-reduction practices (material offcuts, recyclable packaging, eco-fabric sourcing) while balancing product performance and cost.
Manage small-batch production runs including scheduling, sequencing, and resource coordination to meet delivery timelines and seasonal demand peaks.
Participate in product photography and content sessions when needed — assist in staging kites, preparing demo units, and providing technical notes for product pages.
Support trade shows, demo events and workshops by preparing show units, demonstrating assembly and repair techniques, and answering technical questions from customers and partners.
Maintain compliance with workplace safety standards — safe handling of resins, adhesives, cutting tools, and compressed-line equipment; maintain MSDS records and PPE availability.

Secondary Functions

Support ad-hoc customer inquiries about custom builds, material choices and performance trade-offs; prepare clear written recommendations and build timelines.
Contribute to the organization’s product roadmap by providing feasibility input on new materials, manufacturing methods, and cost trade-offs.
Collaborate with procurement to evaluate new vendors for technical fabrics, carbon tubing and rigging supplies; run sample evaluations and approval tests.
Participate in sprint planning, production planning or agile product-development cycles when working with cross-functional teams on new releases.
Document and digitize legacy patterns, transcribing hand-drawn templates into CAD files for reproducible production and backup.
Assist in inventory audits, cycle counts and reorder threshold setting for critical materials to avoid production delays.
Coordinate with shipping and logistics to ensure fragile or high-value kites are packaged and shipped according to carrier and insurance requirements.
Support marketing by providing technical specifications, care instructions and short how-to guides (rigging, launching, tuning) to improve customer satisfaction and reduce returns.

Required Skills & Competencies

Hard Skills (Technical)

Advanced pattern drafting for flexible membrane structures — translating 2D panels into 3D flying shapes.
Proficiency with CAD or vector tools used for patterning (Rhino, SolidWorks, Adobe Illustrator, Inkscape).
Industrial sewing and hand-sewing skills for technical fabrics; experience with heavy-duty machines, walking foot, zigzag and bartack operations.
Composite handling and spar assembly: carbon fiber layup, tube joining, epoxy/resin use, and finishing for lightweight structural members.
Precision cutting techniques: manual templates, straight knives, band knives, or CNC/plotter cutting systems.
Material science knowledge for textile selection (ripstop grades, denier, coatings, stretch behavior) and reinforcement strategies.
Quality assurance and inspection methods, including dimensional tolerance checks and destructive/non-destructive testing for prototypes.
Wind-testing and flight-tuning experience; ability to interpret flight behavior to drive design changes.
Tooling, jig design and small-batch production setup skills, including cost and time estimation for runs.
Repair/restoration skills and ability to evaluate and execute structural fixes with long-term durability.
Basic shop math and measurement skills, metric and imperial proficiency, and ability to create accurate BOMs and material cut-lists.
Familiarity with packaging standards and preparation for retail/ direct-to-consumer shipping.

Soft Skills

Meticulous attention to detail and commitment to consistent finish quality on both handcrafted and production units.
Problem-solving mindset with a pragmatic approach to prototyping and iterative improvement.
Clear verbal and written communication — able to explain technical options to non-technical customers and colleagues.
Time management and ability to prioritize jobs in a small-batch production environment with deadlines.
Team collaboration skills for working across design, sales, and fulfillment functions.
Customer service orientation — courteous, empathetic and solution-focused on custom orders and repairs.
Adaptability and willingness to learn new materials, tools and production techniques.
Coaching and mentorship — patient when teaching apprentices and documenting SOPs.

Education & Experience

Educational Background

Minimum Education:

High school diploma or equivalent with demonstrated hands-on experience in textile fabrication, sewing, woodworking or composites.

Preferred Education:

Associate's or Bachelor’s degree in Industrial Design, Textile Design, Mechanical Engineering, Fine Arts or a related craft/technical discipline.

Relevant Fields of Study:

Industrial or Product Design
Textile Technology or Apparel Construction
Mechanical Engineering, Composites, or Materials Science
Fine Arts / Craftsmanship with a focus on three-dimensional construction

Experience Requirements

Typical Experience Range:

1–7 years of hands-on experience in kite fabrication, sailmaking, outdoor gear production, or related textile/composite manufacturing.

Preferred:

3+ years of direct experience as a kite maker, sailmaker, or technical fabricator with a portfolio of produced designs, flight-tested prototypes, and documented repairs.