Senior Materials, Process, & Test Engineer

Electra•Manassas, VA

3d•$130,000 - $160,000•Onsite

About The Position

Electra.aero, a next-gen aerospace technology company, seeks a dynamic and driven Senior Materials, Process, & Test Engineer. This role will lead the development, selection, testing, and certification of advanced materials and processes for Electra's 9-passenger hybrid-electric eSTOL (electric short takeoff and landing) aircraft. The ideal candidate will have a strong background in aerospace materials and processes, structural and environmental testing, and certification pathways. This role requires a hands-on engineer who thrives in a collaborative, fast-paced environment and is excited to shape the materials and processes that enable next-generation aviation.

Requirements

Bachelor's degree in Materials Science, Mechanical, or Aerospace Engineering (or related STEM discipline).
Minimum 5+ years of experience in aerospace materials and processes, including composite and metallic structures.
Expertise in aerospace material systems (metallic alloys, composites, adhesives, coatings, etc.).
Strong understanding of material processing methods (lamination, curing, heat treatment, bonding, welding, additive manufacturing, etc.).
Experience in design, planning, and execution of structural and environmental test programs.
Knowledge of certification pathways for materials and processes under FAA Part 23 or Part 25.
High competence with engineering fundamentals and ability to translate test data into actionable design/process insights.
Excellent organizational, analytical, and communication skills.
Strong work ethic and ability to independently lead projects from concept through validation.

Nice To Haves

Excellent communication, interpersonal, and leadership skills.

Responsibilities

Developing and qualifying new materials, processes, and joining technologies for composite and metallic airframe structures.
Leading material and process specifications, including supplier coordination and approval.
Designing and executing test campaigns (coupon-level through full-scale) to validate performance, safety, and compliance.
Applying knowledge of FAA Part 23 requirements, ASTM standards, and industry best practices for materials and process qualification.
Driving structural and material trade studies to balance weight, manufacturability, durability, and cost.
Supporting failure investigations, root-cause analysis, and corrective actions related to material performance.
Interfacing with suppliers and manufacturing teams to ensure successful process implementation and scale-up.
Preparing and presenting at internal and external design/test reviews to demonstrate compliance and readiness.
Communicating technical information effectively across engineering teams, leadership, suppliers, and regulatory bodies.