Senior Manufacturing Engineer – Sheet Metal Fabrication

Electra Aero•Manassas, VA

21h•Onsite

About The Position

At Electra, we are developing the EL9, a nine-passenger, hybrid-electric aircraft capable of ultra-short takeoffs and landings (150 feet). This technology aims to enable Direct Aviation, offering quiet, point-to-point regional travel without the congestion of major airports. Electra is a global company headquartered in Manassas, VA, supported by Lockheed Martin, Honeywell, and Safran, and is pursuing FAA Part 23 type certification with over 2,000 intent-to-purchase orders. The company, with approximately 100 employees, is rapidly progressing towards first EL9 test flights in 2027 and certification by late 2029 or 2030. As the Senior Manufacturing Engineer – Sheet Metal Fabrication, you will be responsible for the manufacturing engineering aspects of sheet metal components and assemblies for the EL9 aircraft. You will work within the Integrated Product Development Team (IPDT) and with internal and external manufacturing partners, applying Design for Manufacturing (DFM) principles to establish efficient, repeatable, and cost-effective fabrication processes from scratch. Your expertise in machining will also be crucial for part finishing and structural integration.

Requirements

Bachelor's degree in Mechanical, Manufacturing, or Aerospace Engineering, or a related field.
8+ years of experience in aerospace manufacturing or production engineering.
Strong experience with sheet metal fabrication processes, including forming, bending, and trimming.
Working knowledge of machining processes such as CNC machining, drilling, and finishing operations.
Solid understanding of GD&T, tolerancing, and dimensional control for formed and machined parts.
Excellent 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 with aerospace sheet metal structures, including skins, ribs, frames, and brackets.
Familiarity with forming simulation, springback compensation, and tooling development.
Background working with aircraft OEMs or Tier 1 suppliers in development and/or production programs.
Knowledge of special processes such as heat treatment, surface treatments, and chemical milling.
Experience integrating machined features with formed components in structural assemblies.
Working knowledge of CAD and PLM tools.

Responsibilities

Serve as the manufacturing engineering focal point for sheet metal fabrication, including forming, bending, trimming, and assembly of metallic components.
Collaborate with design and stress engineering teams to incorporate DFM principles into sheet metal part and assembly design.
Define and implement manufacturing requirements for sheet metal components, including material selection, forming methods, tolerancing, and producibility.
Develop and optimize sheet metal processes: press forming, stretch forming, brake forming, roll forming, trimming, and deburring.
Define, specify, and coordinate tooling and fixtures, including dies, forming tools, templates, and check fixtures.
Interface with Tier 1 and Tier 2 suppliers specializing in sheet metal fabrication to ensure alignment on requirements, schedule, cost, quality, and risk.
Conduct trade studies and resolve technical challenges related to forming feasibility, springback, distortion, and dimensional control.
Apply machining process knowledge (CNC trimming, drilling, finishing) to support part completion, tolerance achievement, and assembly integration.
Establish and document manufacturing standards, work instructions, and best practices for sheet metal fabrication and finishing operations.
Support make vs. buy decisions and supplier selection strategies for metallic components.
Contribute to the development of a greenfield fabrication capability, including process flow, factory layout, and equipment selection.