Senior Materials, Process, & Test Engineer

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

Benefits offered by this job

Medical, dental, vision insurance

Paid time off and company holidays

401(k) plan with immediate vesting

Job summary

Electra Aero in Manassas, VA is seeking a qualified professional to develop and qualify materials and processes for aerospace applications. You will lead specifications, execute testing, and ensure compliance with FAA regulations.

The ideal candidate holds a Bachelor’s degree in a relevant field and has over 5 years of experience in aerospace. A comprehensive benefits package, including medical and 401(k), is offered.

Qualifications

• Minimum 5+ years of experience in aerospace materials and processes, including composite and metallic structures.
• High competence with engineering fundamentals and ability to translate test data into actionable insights.

Responsibilities

• Developing and qualifying new materials and processes for aerospace applications.
• Leading material and process specifications with supplier coordination.
• Designing and executing test campaigns to validate performance.
• Driving structural and material trade studies to balance key factors.
• Preparing and presenting internal and external design/test reviews.

Skills

Expertise in aerospace material systems

Strong understanding of material processing methods

Experience in design and execution of test programs

Knowledge of certification pathways under FAA

Excellent organizational and communication skills

Education

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

Tools

Siemens NX CAD

Teamcenter PLM software

Job description

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.

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. Individual pay is based on additional factors, including project budgets, job-related skills, experience, relevant education and/or training, role, level, location, and project.

Compensation and Benefits

Electra offers a comprehensive benefits package including medical, dental, vision, STD, LTD, and life insurance, paid time off, company holidays, and a 401(k) plan with immediate vesting. The company may offer additional perks as part of the total rewards package.