Principal Manufacturing Engineer – Aircraft Systems Installation

Electra.aero; Manassas (VA); On-site; USD 90,000 - 120,000; Full time

Benefits offered by this job

Competitive salary

Medical, dental, and vision insurance

Generous PTO and company holidays

Free catered lunches

Job summary

Electra.aero is seeking a Principal Manufacturing Engineer – Systems Installation in Manassas, VA. In this role, you will lead the manufacturing engineering effort for aircraft systems integration on the EL9 aircraft, focusing on electrical and avionics systems installation. With over 10 years of aerospace manufacturing experience, you will implement design-for-manufacturing principles and develop installation processes. The position offers competitive salary, comprehensive benefits including health insurance, 401(k) with immediate vesting, and a dynamic work environment.

Qualifications

• 10+ years of experience in aerospace manufacturing or production engineering.
• Experience with aircraft systems installation, including EWIS and avionics integration.
• Proven ability to influence multidisciplinary teams.

Responsibilities

• Lead the manufacturing engineering effort for aircraft systems installation.
• Define and implement manufacturing requirements for system installation.
• Develop and deploy installation processes using Lean Manufacturing principles.

Skills

Collaborative communication

Systems installation

Cross-functional coordination

Design for Manufacturing (DFM)

Design for Assembly (DFA)

Education

Bachelor's degree in Electrical Engineering

Bachelor's degree in Aerospace Engineering

Tools

CAD tools

PLM tools

MES tools

Job description

Overview

At Electra, we're building the EL9 – a nine-passenger, hybrid-electric aircraft. Our Ultra Short technology unlocks thousands of new operating locations and enables Direct Aviation: quiet, point-to-point regional travel that avoids major airports and noise from conventional aviation. Electra is a global company headquartered in Manassas, VA, backed by Lockheed Martin, Honeywell, and Safran, and pursuing FAA Part 23 type certification. We are a team of ~100 moving toward first EL9 test flights in 2027 and certification by late 2029 or 2030. Every hire matters at this stage, and this role is essential.

The role described here is for the Principal Manufacturing Engineer – Systems Installation, who will lead the manufacturing engineering effort for aircraft systems integration on the EL9, a clean-sheet Part 23 aircraft. Embedded in our Integrated Product Development Team (IPDT), the focus is on electrical and avionics systems installation, applying design-for-manufacturing (DFM) and design-for-assembly (DFA) principles to enable efficient, scalable final assembly operations, and ensuring production test processes are built in from day one.

The Role

As our Principal Manufacturing Engineer – Systems Installation, you will:

• Lead the manufacturing engineering effort for aircraft systems installation (EWIS and avionics).
• Collaborate with product engineering and systems teams to apply DFM/DFA principles to system design.
• Collaborate with systems engineering, avionics, and software teams to integrate Design for Test (DFT) principles into system architecture.
• Define and implement manufacturing requirements for system installation and integration.
• Develop and deploy installation processes and work instructions using Lean Manufacturing principles.
• Define, specify, and coordinate tooling, fixtures, and installation aids for systems installation.
• Interface between manufacturing, engineering, program teams, and suppliers to align 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 and integration testing and validation procedures.
• Define, specify, and coordinate test equipment, rigs, benches, and automated test systems.
• Ensure alignment between design, manufacturing, and test requirements to meet 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 implementing a greenfield final assembly line, including assembly flow, factory layout, and installation zones.

What You Bring

• 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.

Bonus Points

• 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.

What We Offer

• Competitive salary and equity.
• Medical, dental, and vision insurance; short-term disability (STD), long-term disability (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.

Compensation and Benefits

In addition to offering an exciting work environment and the opportunity to be part of the team making Ultra Short flight a reality, Electra offers a comprehensive benefits package including medical, dental, vision, STD, LTD, and life insurance, generous PTO and sick leave, company holidays, paid winter break, and a 401(k) plan with immediate vesting. Life at Electra includes perks such as free catered lunches, coffee, snacks, drinks, fruit, free parking, and more.

Working Conditions

Work is typically performed in a warehouse/aviation and office environment with proper safety precautions. Some physical effort may be required to handle light materials, boxes, prototypes, and equipment. Some fieldwork may be required in indoor and outdoor conditions. You may need to lift up to 50 lbs.

Background & Drug Screening

Successful completion of a background check and/or drug screening prior to starting may be required.

Commitment

Electra is committed to fostering diversity and inclusivity and encourages individuals from all backgrounds to apply. Electra is an equal opportunity employer and will provide reasonable accommodations for qualified individuals. Electra is an E-Verify employer.