Staff Materials, Process, & Test Engineer

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.