What are the responsibilities and job description for the Principal Manufacturing Engineer - Primary Structures position at Electra.aero?
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 our Principal Manufacturing Engineer – Primary Structures, you'll take on one of the most consequential roles in the EL9 build: owning manufacturability and integration for major load-bearing structures - fuselage, wing, empennage, and primary structural assemblies. Working within our Integrated Product Development Team (IPDT), you'll serve as the technical interface with Tier 1 structural suppliers and internal teams, enabling scalable production systems and ensuring structural integrity from the start.
What You'll Do
In addition to offering an exciting work environment and the opportunity to be part of the team making Ultra Short flight a reality, at Electra, we offer an unparalleled total rewards package. Electra offers employees a comprehensive benefits package including medical, dental, vision, STD, LTD, and life insurance, generous PTO and sick leave, company holidays, paid winter break, and a 401(k) plan with immediate vesting. Life at Electra includes a variety of perks, such as free catered lunches, amazing coffee, snacks, drinks, fruit, free parking, and opportunities for much more.
Working Conditions
Work is typically performed in a warehouse/aviation and office environment, which requires proper safety precautions. Work may require some physical effort in handling light materials, boxes, power tools, prototypes, and different materials or equipment. Due to the nature of our business and projects, some fieldwork may be required, working in both indoor and outdoor conditions. You may need to lift up to 50 lbs.
Background & Drug Screening
Successful completion of a background check and/or drug screening prior to starting work may be required for this position.
Commitment
We are committed to fostering diversity and inclusivity, and we encourage individuals from all backgrounds, including those from marginalized or underrepresented groups in the tech industry and aerospace, to apply for our job openings. We firmly believe that a diverse range of perspectives can profoundly influence both our product and our company culture.
Electra is committed to a work environment that is inclusive to all and free of discrimination. It is our policy to be an equal opportunity employer without regard to race, color, religion, sex, age, national origin, disability, sexual orientation, gender identity or expression, genetic predisposition or carrier status, veteran status, citizenship status, or any other factors prohibited by law. Electra will provide reasonable accommodations for qualified individuals.
Electra is an E-Verify employer.
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 our Principal Manufacturing Engineer – Primary Structures, you'll take on one of the most consequential roles in the EL9 build: owning manufacturability and integration for major load-bearing structures - fuselage, wing, empennage, and primary structural assemblies. Working within our Integrated Product Development Team (IPDT), you'll serve as the technical interface with Tier 1 structural suppliers and internal teams, enabling scalable production systems and ensuring structural integrity from the start.
What You'll Do
- Serve as the manufacturing engineering focal point for primary structures fabrication and assembly throughout product development.
- Lead coordination with Tier 1 suppliers and internal manufacturing teams supporting major structural assemblies (fuselage sections, wing structures, empennage).
- Ensure alignment on requirements, schedule, cost, quality, and risk to meet program objectives.
- Act as the primary liaison between product engineering, stress/structures teams, and suppliers, ensuring robust integration into final aircraft assembly.
- Define and implement manufacturing requirements and build strategies for primary structures, including assembly sequencing, joining methods, tolerancing, and structural interfaces.
- Coordinate development and integration of tooling, fixtures, and capital equipment required for fabrication and assembly of large structural components.
- Perform trade studies and resolve complex technical challenges related to structural assembly, dimensional control, and producibility.
- Support development of assembly concepts (jig-based, pulse line, moving line) and integration into the overall aircraft production system.
- Contribute to the design and implementation of a greenfield manufacturing facility, including factory layout, assembly flow, and industrialization strategy.
- Bachelor's degree in Mechanical, Aerospace, Manufacturing, Materials Engineering, or a related field from an accredited institution.
- 10 years of experience in aerospace manufacturing or production engineering.
- Proven experience with large primary structural assemblies, metallic and/or composite.
- Strong understanding of aircraft structural assembly processes, including fastening, joining, and tolerance management.
- Excellent cross-functional communication and collaboration skills.
- Demonstrated ability to lead and influence multidisciplinary teams, including suppliers.
- Equivalent combinations of education and experience will be considered.
- Experience with primary structures development and assembly in a Part 23 or Part 25 aircraft program.
- Background supporting aircraft OEMs or Tier 1 structural suppliers in both development and production environments.
- Knowledge of assembly tooling strategies, dimensional control systems, and production ramp-up.
- Familiarity with CAD and PLM systems.
- Experience with production system design, including takt-driven assembly lines and industrialization planning.
- 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.
In addition to offering an exciting work environment and the opportunity to be part of the team making Ultra Short flight a reality, at Electra, we offer an unparalleled total rewards package. Electra offers employees a comprehensive benefits package including medical, dental, vision, STD, LTD, and life insurance, generous PTO and sick leave, company holidays, paid winter break, and a 401(k) plan with immediate vesting. Life at Electra includes a variety of perks, such as free catered lunches, amazing coffee, snacks, drinks, fruit, free parking, and opportunities for much more.
Working Conditions
Work is typically performed in a warehouse/aviation and office environment, which requires proper safety precautions. Work may require some physical effort in handling light materials, boxes, power tools, prototypes, and different materials or equipment. Due to the nature of our business and projects, some fieldwork may be required, working in both indoor and outdoor conditions. You may need to lift up to 50 lbs.
Background & Drug Screening
Successful completion of a background check and/or drug screening prior to starting work may be required for this position.
Commitment
We are committed to fostering diversity and inclusivity, and we encourage individuals from all backgrounds, including those from marginalized or underrepresented groups in the tech industry and aerospace, to apply for our job openings. We firmly believe that a diverse range of perspectives can profoundly influence both our product and our company culture.
Electra is committed to a work environment that is inclusive to all and free of discrimination. It is our policy to be an equal opportunity employer without regard to race, color, religion, sex, age, national origin, disability, sexual orientation, gender identity or expression, genetic predisposition or carrier status, veteran status, citizenship status, or any other factors prohibited by law. Electra will provide reasonable accommodations for qualified individuals.
Electra is an E-Verify employer.