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Senior Structural Assembly Manufacturing Engineer

Manassas, VA; Olten, Solothurn, Switzerland

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

As Electra's Senior Structural Assembly Manufacturing Engineer, you'll play a key role in developing and industrializing the structural assembly processes for the EL9 aircraft, working from early product development through prototype build, production implementation, and ramp-up.

You'll work closely with Product Engineering during aircraft development to ensure structural designs incorporate Design for Manufacturing and Assembly (DFMA) principles and can be efficiently, repeatably, and reliably produced. You'll bring a hands-on manufacturing perspective to structural design decisions, evaluating assembly sequence, tolerance management, access, tooling, fastening and joining methods, inspection requirements, producibility, and production risk.

As the EL9 transitions from design into physical hardware, you'll help translate released engineering into executable manufacturing processes and support prototype and initial aircraft builds. You'll work closely with airframe manufacturing suppliers, providing on-site Manufacturing Engineering oversight and liaison support as needed to ensure proper information flow, resolve technical and quality issues, support the incorporation of product changes and support supply chain on contract management.

This is an opportunity to influence both how the aircraft is designed and how it is ultimately built, while helping establish Electra's structural assembly manufacturing supply chain capability from the ground up.

What You'll Do

  • Partner with Product Engineering throughout aircraft development to ensure structural designs incorporate Design for Manufacturing and Assembly (DFMA) principles and support efficient, repeatable, and scalable production.
  • Review aircraft structural designs, assemblies, drawings, models, and engineering changes from a manufacturing perspective, providing recommendations related to producibility, assembly sequence, access, tolerance stack-up, fastening and joining methods, tooling, inspection, and production risk.
  • Participate in design trade studies, concept reviews, and design reviews, representing Manufacturing Engineering and identifying manufacturing constraints and opportunities early in the development cycle.
  • Provide Manufacturing Engineering oversight and liaison support at airframe and structural suppliers, working directly with supplier manufacturing teams to clarify design and manufacturing intent, resolve producibility and assembly issues, and maintain program execution.
  • Work closely with the airframe supplier Tooling Engineering to define assembly tooling concepts, requirements, locating strategies, interfaces, and implementation plans.
  • Review supplier manufacturing approaches, build plans, assembly processes, tooling concepts, and production readiness to ensure alignment with Electra's engineering requirements and program objectives.
  • Support prototype fabrication, development aircraft assembly, first builds, and production implementation, providing hands-on Manufacturing Engineering support to resolve issues encountered during structural assembly.
  • Coordinate technical resolution of manufacturing issues and nonconformances with Product Engineering, Stress, Quality, Supplier Quality, Supply Chain, and other stakeholders.
  • Capture manufacturing lessons learned and supplier feedback from prototype and initial production builds and drive those learnings back into product design, manufacturing processes, tooling, and planning.
  • Support structural assembly production ramp-up by identifying constraints, resolving manufacturing issues, improving assembly processes, and driving improvements in quality, cost, schedule, and production rate.
  • Contribute to the development and continuous improvement of Electra manufacturing engineering standards, methods, processes, and best practices.

What You Bring

  • Bachelor's degree in Mechanical, Aerospace, Aeronautical, Manufacturing Engineering, or a related engineering field.
  • 8+ years of aerospace manufacturing engineering experience, with significant experience in aircraft structural assembly and industrialization.
  • Strong hands-on knowledge of aircraft structural assembly processes, including metallic and/or composite airframe structures, drilling, fastening, joining, shimming, sealing, alignment, and major structural integration.
  • Demonstrated experience applying Design for Manufacturing and Assembly (DFMA) principles during aircraft product development.
  • Experience reviewing engineering drawings, 3D models, GD&T, tolerances, and engineering changes from a manufacturing and assembly perspective.
  • Experience developing manufacturing plans, assembly sequences, work instructions, tooling requirements, and manufacturing engineering documentation.
  • Experience supporting prototype, development, or first-production aircraft builds.
  • Experience working directly with aircraft structures suppliers or manufacturing partners and supporting production activities in a factory environment.
  • Demonstrated ability to work effectively across Product Engineering, Stress, Quality, Supplier Quality, Supply Chain, Tooling, and Production organizations.
  • Strong problem-solving skills and ability to make sound engineering recommendations in a fast-moving aircraft development environment.
  • Strong written and verbal communication skills, with the ability to work effectively across internal teams and external suppliers.
  • Ability and willingness to travel to supplier and manufacturing locations as required by program needs.

Bonus Points

  • Experience with clean-sheet aircraft development and transition from prototype into production.
  • Experience with major structural assemblies such as fuselage, wing, empennage, control surfaces, or other primary airframe structures.
  • Experience with aircraft assembly tooling, jigs, fixtures, determinant assembly, or advanced assembly methodologies.
  • Experience with digital manufacturing tools, PLM/MES environments, manufacturing BOMs, and 3D model-based manufacturing.
  • Experience with supplier industrialization, production readiness assessments, or manufacturing capability reviews.
  • Experience with MRB, root cause corrective action, and production nonconformance resolution.
  • Experience with AS9100 aerospace quality management systems.

 

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

$130,000 - $155,000 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.

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