Principal Manufacturing Engineer – Systems Installation

Electra Aero•Manassas, VA

23h•Onsite

About The Position

Electra is building the EL9, a nine-passenger, hybrid-electric aircraft designed for Ultra Short technology, enabling quiet, point-to-point regional travel. Headquartered in Manassas, VA, Electra is backed by Lockheed Martin, Honeywell, and Safran, and is working towards FAA Part 23 type certification with first EL9 test flights in 2027 and certification by late 2029 or 2030. The company is a team of approximately 100 people. The Principal Manufacturing Engineer – Systems Installation will lead the manufacturing engineering effort for aircraft systems integration on the EL9, focusing on electrical and avionics systems installation. This role involves applying Design for Manufacturability (DFM) and Design for Assembly (DFA) principles to achieve efficient, scalable final assembly operations, and ensuring production test processes are integrated from the outset.

Requirements

Bachelor's degree in Electrical Engineering, Aerospace Engineering, or a related field.
10+ years of experience in aerospace manufacturing or production engineering.
Experience with aircraft systems installation, including EWIS and avionics integration.
Strong cross-functional communication and collaboration skills.
Proven ability to influence multidisciplinary teams and coordinate with suppliers.
Equivalent combinations of education and experience will be considered.

Nice To Haves

Experience supporting aircraft systems installation during development and/or production programs.
Background working at an aircraft OEM or Tier 1 supplier.
Familiarity with assembly sequencing, zoning, and installation planning.
Working knowledge of CAD, PLM, and MES tools.

Responsibilities

Serve as the manufacturing engineering focal point for aircraft systems installation, including electrical wiring interconnect systems (EWIS) and avionics.
Collaborate with product engineering and systems teams to incorporate DFM/DFA principles into system design.
Collaborate with systems engineering, avionics, and software teams to ensure Design for Test (DFT) principles are incorporated into system architecture.
Define and implement manufacturing requirements for system installation and integration.
Develop and deploy installation processes and work instructions, leveraging Lean Manufacturing principles.
Define, specify, and coordinate tooling, fixtures, and installation aids required for systems installation.
Act as the interface between manufacturing, engineering, program teams, and suppliers, ensuring alignment on requirements, schedule, cost, and quality.
Conduct trade studies and resolve technical challenges related to systems installation and integration in final assembly.
Support development of assembly sequencing and installation strategies for aircraft systems.
Define and implement test requirements, strategies, and procedures for aircraft systems during final assembly.
Develop and deploy production test processes, including functional testing, integration testing, and validation procedures.
Define, specify, and coordinate the implementation of test equipment, rigs, benches, and automated test systems.
Ensure alignment between design, manufacturing, and test requirements to meet program schedule, cost, and quality objectives.
Conduct trade studies and resolve complex technical challenges related to systems testing and validation.
Establish and document testability, diagnostics, and fault isolation best practices.
Contribute to the implementation of a greenfield final assembly line, including assembly flow, factory layout, and installation zones.

Benefits

Competitive salary and equity.
Medical, dental, and vision insurance; STD, LTD, and life insurance.
Generous PTO, sick leave, and company holidays.
Paid winter break.
401(k) with immediate vesting.
Free catered lunches, coffee, snacks, and drinks at our Manassas headquarters.
Comprehensive benefits package including medical, dental, vision, STD, LTD, and life insurance.
Generous PTO and sick leave.
Company holidays.
Paid winter break.
401(k) plan with immediate vesting.
Free catered lunches, amazing coffee, snacks, drinks, fruit.
Free parking.