Senior Materials, Process & Test Engineer – Aerospace

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

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