Staff Materials, Process, & Test Engineer

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

Benefits offered by this job

Medical, dental, and vision insurance

Paid time off and holidays

401(k) with employer match

Free catered lunches and on-site perks

On-site parking

Job summary

Electra.aero seeks a Staff Materials, Process, & Test Engineer to lead development, qualification, and certification of advanced materials for the EL9 aircraft. You will steer material systems, testing programs, and certification pathways, collaborating across suppliers and internal teams.

The role requires 5+ years in aerospace materials and processes, strong testing experience, and the ability to translate test data into design insight.

Qualifications

• Requires a Bachelor's in a STEM field with aerospace materials focus.
• Experience leading test programs for structural and environmental testing.
• Knowledge of aerospace material systems and processing methods.

Responsibilities

• Lead development, qualification, and certification of advanced materials and processes for airframe structures.
• Coordinate material specifications, supplier engagements, and approvals.
• Plan and execute coupon-level to full-scale test campaigns to validate performance and safety.
• Apply FAA Part 23/25 knowledge and industry standards for material qualification.
• Support structural/material trade studies balancing weight, manufacturability, durability, and cost.
• Assist in root-cause analysis and corrective actions for material performance issues.
• Interface with suppliers and manufacturing teams to implement processes at scale.
• Prepare and present at design/test reviews to demonstrate compliance and readiness.
• Communicate technical information across teams, leadership, suppliers, and regulators.
• Mentor junior engineers on materials and process best practices.

Skills

Aerospace materials

Structural testing

Materials processing

Test program planning

Cross-functional collaboration

Technical communication

Education

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

Job description

About Electra

Air travel is about to become something more: more direct, more accessible, and more connected to the places where people live, work and want to be. Every day in the U.S., people make 35 million trips of 50–500 miles, stuck in traffic or routed through crowded hubs. Chances are, you've been one of them. At Electra, we're changing that with the EL9, a nine-passenger, hybrid-electric aircraft that takes off and lands in just 150 feet. Our Ultra Short technology opens up thousands of new places to fly, beyond conventional runways, congested airports and long drives. We're backed by Lockheed Martin, Honeywell and Safran. Operators worldwide have signed intent-to-purchase agreements for the first 2,200 aircraft we produce, and we're moving toward first test flights in 2027.

Getting a new kind of aircraft airborne takes more than ambition. It takes our kind of bold: people who think big while working in the real world. Who move ideas into action and collaborate without silos. Who put people first and make room at the table for everyone. Who challenge one another without diminishing one another.

Sound like you? Then look beyond what you thought were your own limits, and help us take flight beyond runways.

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 USD - $136,000 USD

What We Offer

• 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.