Senior Manufacturing Engineer – Sheet Metal Fabrication
Electra Aero•Manassas, VA
•Onsite
About The Position
As our Senior Manufacturing Engineer – Sheet Metal Fabrication, you'll own the manufacturing engineering function for sheet metal components and assemblies on the EL9 - a clean-sheet Part 23 aircraft. Working within our Integrated Product Development Team (IPDT) and alongside internal and external manufacturing partners, you'll apply Design for Manufacturing (DFM) principles to build efficient, repeatable, cost-effective fabrication processes from the ground up. Machining knowledge will round out your contribution across 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.
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.
- Free on-site parking.
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What This Job Offers
Job Type
Full-time
Career Level
Senior
Number of Employees
11-50 employees
