Senior Manufacturing Engineer Jobs in Reston, VA

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 Senior Manufacturing Engineer, you'll lead the manufacturing engineering effort for aircraft systems integration on the EL9, a clean-sheet Part 23 aircraft. Embedded in our Integrated Product Development Team (IPDT), your focus will be on electrical and avionics systems installation, applying DFM and DFA principles to enable efficient, scalable final assembly operations - and ensuring production test processes are built in from day one.

What You'll Do

• Serve as the manufacturing engineering focal point for aircraft systems installation, including electrical wiring interconnect systems (EWIS) and avionics.
• Collaborate with product engineering and systems teams to incorporate DFM/DFA principles into system design.
• Collaborate with systems engineering, avionics, and software teams to ensure Design for Test (DFT) principles are incorporated into system architecture.
• Define and implement manufacturing requirements for system installation and integration.
• Develop and deploy installation processes and work instructions, leveraging Lean Manufacturing principles.
• Define, specify, and coordinate tooling, fixtures, and installation aids required for systems installation.
• Act as the interface between manufacturing, engineering, program teams, and suppliers, ensuring alignment on requirements, schedule, cost, and quality.
• Conduct trade studies and resolve technical challenges related to systems installation and integration in final assembly.
• Support development of assembly sequencing and installation strategies for aircraft systems.
• Define and implement test requirements, strategies, and procedures for aircraft systems during final assembly.
• Develop and deploy production test processes, including functional testing, integration testing, and validation procedures.
• Define, specify, and coordinate the implementation of test equipment, rigs, benches, and automated test systems.
• Ensure alignment between design, manufacturing, and test requirements to meet program schedule, cost, and quality objectives.
• Conduct trade studies and resolve complex technical challenges related to systems testing and validation.
• Establish and document testability, diagnostics, and fault isolation best practices.
• Contribute to the implementation of a greenfield final assembly line, including assembly flow, factory layout, and installation zones.

What You Bring

• Bachelor's degree in Electrical Engineering, Aerospace Engineering, or a related field.
• 8+ years of experience in aerospace manufacturing or production engineering.
• Experience with aircraft systems installation, including EWIS and avionics integration.
• Strong cross-functional communication and collaboration skills.
• Proven ability to influence multidisciplinary teams and coordinate with suppliers.
• Equivalent combinations of education and experience will be considered.

Bonus Points

• Experience supporting aircraft systems installation during development and/or production programs.
• Background working at an aircraft OEM or Tier 1 supplier.
• Familiarity with assembly sequencing, zoning, and installation planning.
• Working knowledge of CAD, PLM, and MES tools.

Compensation

$110,000 – $135,000 annually. 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.

What We Offer

• 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.

Compensation and Benefits

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.