Senior Materials, Process & Test Engineer – Aerospace

Electra; Manassas (VA); On-site; USD 112,000 - 136,000; Full time

Benefits offered by this job

Competitive salary

Equity

Medical, dental, and vision insurance

Generous PTO and holidays

Free catered lunches and drinks at Man

Free on-site parking

401(k) with immediate vesting

Winter break

Job summary

Electra seeks a Staff Materials, Process, & Test Engineer to lead development, selection, testing, and certification of advanced materials for our EL9 hybrid-electric aircraft. You will drive material systems, processing methods, and test programs across composite and metallic airframe structures.

The role requires 5+ years in aerospace materials, strong FAA Part 23/25 knowledge, and proven ability to lead cross‑functional projects in a fast‑paced setting.

Qualifications

• Bachelor's degree in Materials Science, Mechanical, or Aerospace Engineering.
• 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.
• Demonstrated ability to independently lead cross‑functional projects and influence technical decisions without direct authority.
• Excellent organizational, analytical, and communication skills.
• Strong work ethic and ability to independently lead projects from concept through validation.

Responsibilities

• Lead development, qualification, and certification of materials and processes for the aircraft.
• Support material and process specifications, supplier coordination, and approvals.
• Design and execute test campaigns from coupon to full-scale to validate performance and safety.
• Apply FAA Part 23/ASTM standards and industry best practices for qualification.
• Contribute to structural/material trade studies balancing weight, manufacturability, durability, and cost.
• Support failure investigations and corrective actions related to material performance.
• Interface with suppliers and manufacturing teams for 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.
• Provide guidance to junior/mid engineers on materials and process best practices.

Skills

Aerospace materials

Materials testing

Structural testing

FAA Part 23/25 knowledge

Project leadership

Education

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

Job description

Electra seeks a Staff Materials, Process, & Test Engineer to lead development, selection, testing, and certification of advanced materials for our EL9 hybrid-electric aircraft. You will drive material systems, processing methods, and test programs across composite and metallic airframe structures.

The role requires 5+ years in aerospace materials, strong FAA Part 23/25 knowledge, and proven ability to lead cross‑functional projects in a fast‑paced setting.