Senior Materials, Process Test Engineer

Overview

Electra.aero, a next-gen aerospace technology company, seeks a dynamic and driven Senior 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.

• Developing and qualifying new materials, processes, and joining technologies for composite and metallic airframe structures.
• Leading material and process specifications, including supplier coordination and approval.
• Designing and executing 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.
• Driving 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.
• Interfacing with suppliers and manufacturing teams to ensure successful process implementation and scale-up.
• Preparing and presenting at internal and external design/test reviews to demonstrate compliance and readiness.
• Communicating technical information effectively across engineering teams, leadership, suppliers, and regulatory bodies.

• 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.

• Demonstrated experience with FAA certification processes for materials and processes.
• Familiarity with Siemens NX CAD and Teamcenter PLM software.
• Competency in material and structural analysis (static, fatigue, thermal, and environmental performance).
• US Person (Citizen or Green Card) preferred.
• PPL

Headquarters in Manassas, VA. To encourage close collaboration, this position is 4-5 days in the office, with some virtual work allowed.

Electra's salary range for this position is: $-. Our salary ranges reflect the minimum and maximum range for the Company level overall across all locations & projects and do not necessarily reflect the budgeted amount for this position. Individual pay is based on additional factors, including project budgets, job-related skills, experience, relevant education and/or training, role, level, location, and project.

Electra’s mission is to develop a hybrid-electric Ultra Short Takeoff and Landing aircraft, designed to transform regional air mobility. We are…