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Principal Structural Design for Manufacturing Engineer

Greensboro, NC

What is JetZero? 

Today’s aircraft contribute around 4% of global CO2 emissions, equivalent to the emissions of 200 million cars. This is only going to increase: Air travel is forecasted to double by 2050, while meaningful efficiency gains using current airplanes have hit a wall. 

JetZero is developing a blended-wing body (BWB) aircraft. It uses up to 50% less fuel and will be built to accommodate zero-emission hydrogen propulsion. JetZero is the inevitable solution to sustainable air travel. 

The JetZero team 

We are experienced aerospace professionals and engineers, excited about the future. That future will only be possible if we share our vision and what it means to people’s lives: carbon-free flight that' is better for both passengers and airlines around the world. 

 

What You'll Do
 
JetZero is looking for a Principal Design for Manufacturing (DFM) Engineer to serve as the critical bridge between structural design and production. This is a senior individual contributor role that requires deep expertise in both aircraft structural design and manufacturing engineering — someone who can speak the language of both disciplines and drive better decisions at the intersection of the two.
As a Principal DFM Engineer, you will be embedded in JetZero's Integrated Product Teams (IPTs), influencing structural architecture decisions from concept through detail design to ensure our Blended Wing Body aircraft is not only structurally sound, but producible, inspectable, and scalable to rate production. You will be a technical authority and mentor, setting DFM standards and practices across the organization.
 
Design for Manufacturing Leadership:
  • Serve as the primary DFM authority within structural IPTs, ensuring manufacturing considerations are incorporated at every stage of the design process
  • Identify and resolve producibility risks early in the design cycle — influencing material selection, tolerances, joint design, part consolidation, and assembly methods before they become downstream production problems
  • Lead DFM trade studies and design reviews, providing actionable guidance to both structural design engineers and manufacturing engineers
  • Champion Model Based Definition (MBD) practices to ensure design intent is accurately and completely communicated to manufacturing
Structural Design Integration:
  • Apply deep knowledge of composite and metallic aircraft structures to evaluate and guide structural architectures for producibility
  • Collaborate with stress, design, and systems engineers to ensure load paths, PSE configurations, and structural interfaces are compatible with planned manufacturing and assembly methods
  • Review and approve engineering drawings, design specifications, and compliance documentation with a DFM lens
  • Support Building Block test program development to validate that structural and manufacturing approaches meet requirements
Manufacturing Process Development:
  • Develop and validate manufacturing processes, tooling strategies, and build sequences aligned to the structural design
  • Define Bills of Process (BOPs) and work package instructions that translate design concepts into production-ready steps
  • Apply and interpret GD&T to ensure structures are dimensioned and toleranced for manufacturability, inspection, and assembly
  • Leverage digital manufacturing tools — including kinematic, robotic, and process simulations — to develop efficient, repeatable assembly approaches
  • Maintain alignment across CAD, BOM, and BOP systems; manage DFM impacts of engineering changes
Standards, Mentorship & Cross-Functional Influence:
  • Establish and maintain DFM guidelines, standards, and best practices for JetZero's structures organization
  • Train and mentor structural design engineers and manufacturing engineers on DFM principles
  • Engage directly with suppliers during design reviews to ensure external designs and processes meet JetZero's producibility requirements
  • Collaborate with Systems, Cabin, and Supply Chain teams to drive integrated, manufacturable solutions at the aircraft level
What You Bring:
  • Bachelor's or Master's degree in Aerospace Engineering, Mechanical Engineering, or a related field
  • 15+ years of combined experience in aircraft structural design and/or manufacturing engineering, with demonstrated expertise in both disciplines
  • Deep knowledge of composite and metallic aircraft structures, including PSEs, load path optimization, joint design (bolted and bonded), and structural architecture
  • Hands-on experience driving DFM in an aerospace product development environment — not just reviewing designs, but actively shaping them
  • Experience developing manufacturing processes, tooling strategies, work packages, BOMs, and BOPs
  • Strong proficiency with Siemens NX; experience with FiberSim and/or Teamcenter a strong plus
  • Solid understanding of GD&T (ASME Y14.5) and its application to structural assemblies
  • Experience with PLM and MES systems in an aerospace development context
  • Proven ability to influence cross-functional teams and communicate complex technical trade-offs to diverse stakeholders
Preferred Skills (Nice to Have):
  • Experience on a new aircraft development program (clean-sheet or major derivative)
  • Familiarity with Siemens Process Simulate or equivalent digital manufacturing tools
  • Experience with composite manufacturing processes (layup, autoclave, OOA, AFP/ATL) and their design implications
  • Prior experience in a technical lead or principal engineer capacity
 
Compensation & Benefits
Our compensation package is a blend of base salary and equity options for eligible employees. The range for this role is $195,000 - $240,000. We consider a number of factors when presenting a final offer, including geography, internal equity and years of experience and expertise.  
 
Benefits:
  • Unlimited PTO
  • 10 paid holidays
  • 401(k)
  • Medical, Dental, Vision, and Life Insurance
  • Disability Insurance
  • Equity tax advisory services
  • Supportive work culture

 

The Interview Process  

We want our interview process to be a true reflection of our culture: transparent and collaborative. Throughout the interview process, your recruiter will guide you through the next steps and ensure you feel prepared every step of the way.  

  • Our First Chat: During this first conversation, you’ll meet with a recruiter or hiring team member to chat through your background, what you could bring to our team, what you are looking for in your next role, and who we are.  
  • The Hiring Manager Interview: You will meet with your potential future boss to really dive into the role, the team, expectations, and what success means at JetZero. This is your chance to really nerd out with someone in your field.  
  • The Panel: Learn more about the team, responsibilities, and workflows. You should be prepared to speak about past projects, how you collaborate and communicate with others, and how you live our values. Depending on the team and role you are interviewing for, you may meet with several teammates as well as cross-functional partners.  
  • The Executive Review: A chance to meet an executive and view JetZero from a different lens. Be prepared to ask well-thought-out questions about the company, culture, and more. 

Depeneding on the position you are interviewing for, there may also be a Take Home Exercise as part of the interview proccess. Our assessments seek to test the hard skills required to do the job. Your recruiter will inform you of which assessment you will be assigned and ensure you are fully prepared for your big day.  

JetZero does not sponsor visas for US positions unless specified. Only applicants with current work authorization will be considered. 

At JetZero, we value diversity and are an equal opportunity employer by choice. We consider all qualified applicants equally for employment & do not discriminate on the basis of race, color, national origin, ancestry, citizenship status, protected veteran status, religion, physical or mental disability, marital status, sex, sexual orientation, gender identity or expression, age, or any other basis protected by federal, state or local laws, ordinance, or regulation.

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