Senior Materials, Process, & Test Engineer

Electra.aero; Manassas (VA); Hybrid; USD 130,000 - 170,000; Full time

Job summary

A cutting-edge aerospace company in Manassas, VA seeks a Senior Materials, Process, & Test Engineer responsible for leading the development and testing of advanced materials. The successful candidate will have over 5 years of aerospace experience and expertise in materials processing, along with a bachelor's degree in a related field. The salary range for this position is competitive, between $130,000 and $170,000, with some remote work flexibility.

Qualifications

• Minimum 5+ years of experience in aerospace materials and processes.
• Demonstrated experience with FAA certification processes.
• Competency in material and structural analysis.

Responsibilities

• Developing and qualifying new materials, processes, and joining technologies.
• Leading material and process specifications, including supplier coordination.
• Designing and executing test campaigns to validate performance.

Skills

Expertise in aerospace material systems

Strong understanding of material processing methods

Experience in design, planning, and execution of structural and environmental test programs

Knowledge of certification pathways for materials and processes

Excellent organizational, analytical, and communication skills

Strong work ethic and ability to independently lead projects

Education

Bachelor's degree in Materials Science, Mechanical, or Aerospace Engineering

Tools

Siemens NX CAD

Teamcenter PLM software

Job description

Overview

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.

Key Responsibilities & Essential Functions

• 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.

Required Education and Experience

• 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.

Required Skills

• 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.

Desired Qualifications

• Demonstrated experience with FAA certification processes for materials and processes.
• Familiarity with Siemens NX CAD and Teamcenter PLM software.
• Competency in material and structural analysis (static, fatigue, thermal, and environmental performance).
• US Person (Citizen or Green Card) preferred.
• PPL

Location

Headquarters in Manassas, VA. To encourage close collaboration, this position is 4-5 days in the office, with some virtual work allowed.

Salary

Electra's salary range for this position is: $130,000.00-170,000.00. Our salary ranges reflect the minimum and maximum range for the Company level overall across all locations & projects and do not necessarily reflect the budgeted amount for this position. Individual pay is based on additional factors, including project budgets, job-related skills, experience, relevant education and/or training, role, level, location, and project.

About Electra

Electra’s mission is to develop a hybrid-electric Ultra Short Takeoff and Landing aircraft, designed to transform regional air mobility. We are redefining the next level of connectivity, pioneering direct aviation – without airports, emissions, or noise. Electra’s Ultra Short aircraft will revolutionize air travel by bringing it closer to where we live, work, and play, making new connections possible. This makes a new venture like Electra exciting and fast-paced. Headquartered in Northern Virginia, we’re on a quest to build a team of insanely talented people who want to do meaningful work.

Equal Opportunity Employer

Electra is committed to fostering diversity and inclusivity, and we encourage individuals from all backgrounds to apply for our job openings. Electra is an equal opportunity employer without regard to race, color, religion, sex, age, national origin, disability, sexual orientation, gender identity or expression, veteran status, citizenship status, or any other factors prohibited by law. Electra will provide reasonable accommodations for qualified individuals. Electra is an E-Verify employer.