Senior Materials, Process, & Test Engineer

About the role

Electra seeks a dynamic and driven Senior Materials, Process, & Test Engineer to 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.

Responsibilities

• Develop and qualify new materials, processes, and joining technologies for composite and metallic airframe structures.
• Lead material and process specifications, including supplier coordination and approval.
• Design and execute test campaigns (coupon-level through full-scale) to validate performance, safety, and compliance.
• Apply knowledge of FAA Part 23 requirements, ASTM standards, and industry best practices for materials and process qualification.
• Drive structural and material trade studies to balance weight, manufacturability, durability, and cost.
• Support failure investigations, root-cause analysis, and corrective actions related to material performance.
• Interface with suppliers and manufacturing teams to ensure successful process implementation and scale-up.
• Prepare and present at internal and external design/test reviews to demonstrate compliance and readiness.
• Communicate technical information effectively across engineering teams, leadership, suppliers, and regulatory bodies.

Requirements

• 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.
• Excellent organizational, analytical, and communication skills.
• Strong work ethic and ability to independently lead projects from concept through validation.

Benefits

• 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

Pay

Compensation Range: $130,000 USD - $160,000 USD. 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.