Senior Materials, Process, & Test Engineer

ELECTRA; Manassas (VA); On-site; USD 130,000 - 160,000; Full time

Benefits offered by this job

Medical, dental, and vision insurance

Sick leave and holidays

401(k) with immediate vesting

Free catered lunches in Manassas

Job summary

Electra is seeking a Senior Materials, Process, & Test Engineer in Manassas, VA to lead materials selection, testing, and certification for the EL9 hybrid-electric aircraft. You will own material systems, processing methods, and qualification strategies across airframe structures in a fast-paced environment.

The successful candidate will navigate composite and metallic structures, drive test campaigns, and collaborate with suppliers and manufacturing to implement scalable processes, ensuring

Qualifications

• Bachelor's degree in Materials Science, Mechanical, or Aerospace Engineering
• Minimum 5+ years of experience in aerospace materials and processes
• Expertise in metallic alloys, composites, adhesives, coatings, etc.
• Strong understanding of material processing methods (lamination, curing, heat treatment, bonding, welding, additive manufacturing)
• 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

Responsibilities

• Develop and qualify materials, processes, and joining technologies for airframe structures (composites and metals).
• Lead material and process specifications, including supplier coordination and approval.
• Design and execute test campaigns from coupon to full-scale to validate performance and safety.
• Apply FAA Part 23/25 knowledge to qualification activities.
• Drive trade studies balancing weight, manufacturability, durability, and cost.
• Support failure investigations and root-cause analyses related to materials.
• Interface with suppliers and manufacturing to ensure process implementation and scale-up.
• Prepare and present at design/test reviews to demonstrate compliance and readiness.
• Communicate technical information across teams, leadership, suppliers, and regulators.

Skills

Aerospace materials

5+ years experience

Material systems

Test programs

Certification knowledge

Leadership

Education

Bachelors in Materials/Mechanical/Aero Eng

Job description

About Electra

At Electra, we’re building the EL9 — a nine-passenger, hybrid-electric aircraft that takes off and lands in 150 feet. Our Ultra Short technology unlocks thousands of new operating locations and enables what we call Direct Aviation: quiet, point-to-point regional travel that gets people from where they are to where they want to go, without the congestion of major airports or the noise of conventional aviation.

A global company, headquartered in Manassas, VA, Electra is backed by Lockheed Martin, Honeywell, and Safran, has filed for FAA Part 23 type certification, and carries 2,000+ intent to purchase from operators worldwide. We’re a team of ~100 people moving fast toward first EL9 test flights in 2027 and certification by late 2029 or 2030. Every hire matters at this stage — and this role is no exception.

The Role

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.

What You’ll Do

• 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.

What You Bring

• 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.

Bonus Points

• Excellent communication, interpersonal, and leadership skills.

This range reflects the anticipated hiring range across all eligible locations; actual compensation is determined based on your relevant experience, skills, and geographic location. Total compensation includes performance bonus and comprehensive benefits.

Compensation Range

$130,000 - $160,000 USD

What We Offer

• 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

Electra is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, disability, veteran status, or any other characteristic protected by law. This position may be subject to ITAR requirements.