Staff Materials, Process, & Test Engineer

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

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 Staff 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

• Supporting the development and qualification of new materials, processes, and joining technologies for composite and metallic airframe structures.
• Assisting with material and process specifications, including supplier coordination and approval.
• Supporting the design and execution of 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.
• Contributing to 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.
• Assisting in interfacing with suppliers and manufacturing teams to support process implementation and scale‑up.
• Helping prepare and present at internal and external design/test reviews to demonstrate compliance and readiness.
• Communicating technical information effectively across engineering teams, leadership, suppliers, and regulatory bodies.
• Providing technical guidance and support to junior and mid‑level engineers on materials and process best practices.

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.
• 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.

Bonus Points

• Excellent communication, interpersonal, and leadership skills.
• Experience mentoring or leading technical teams.

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

$112,000 - $136,000 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.

Voluntary Self-Identification

For government reporting purposes, we ask candidates to respond to the below self-identification survey. Completion of the form is entirely voluntary. Whatever your decision, it will not be considered in the hiring process or thereafter. Any information that you do provide will be recorded and maintained in a confidential file.

As set forth in Electra’s Equal Employment Opportunity policy, we do not discriminate on the basis of any protected group status under any applicable law.

If you believe you belong to any of the categories of protected veterans listed below, please indicate by making the appropriate selection. As a government contractor subject to the Vietnam Era Veterans Readjustment Assistance Act (VEVRAA), we request this information in order to measure the effectiveness of the outreach and positive recruitment efforts we undertake pursuant to VEVRAA. Classification of protected categories is as follows:

A "disabled veteran" is one of the following: a veteran of the U.S. military, ground, naval or air service who is entitled to compensation (or who but for the receipt of military retired pay would be entitled to compensation) under laws administered by the Secretary of Veterans Affairs; or a person who was discharged or released from active duty because of a service-connected disability.

A "recently separated veteran" means any veteran during the three‑year period beginning on the date of such veteran's discharge or release from active duty in the U.S. military, ground, naval, or air service.

An "active duty wartime or campaign badge veteran" means a veteran who served on active duty in the U.S. military, ground, naval or air service during a war, or in a campaign or expedition for which a campaign badge has been authorized under the laws administered by the Department of Defense.

An "Armed forces service medal veteran" means a veteran who, while serving on active duty in the U.S. military, ground, naval or air service, participated in a United States military operation for which an Armed Forces service medal was awarded pursuant to Executive Order 12985.