The Role

As our Senior Manufacturing Engineer - Sheet Metal Fabrication, you'll own the manufacturing engineering function for sheet metal components and assemblies on the EL9 - a clean-sheet Part 23 aircraft. Working within our Integrated Product Development Team (IPDT) and alongside internal and external manufacturing partners, you'll apply Design for Manufacturing (DFM) principles to build efficient, repeatable, cost-effective fabrication processes from the ground up. Machining knowledge will round out your contribution across part finishing and structural integration.

What You'll Do

• Serve as the manufacturing engineering focal point for sheet metal fabrication, including forming, bending, trimming, and assembly of metallic components.
• Collaborate with design and stress engineering teams to incorporate DFM principles into sheet metal part and assembly design.
• Define and implement manufacturing requirements for sheet metal components, including material selection, forming methods, tolerancing, and producibility.
• Develop and optimize sheet metal processes: press forming, stretch forming, brake forming, roll forming, trimming, and deburring.
• Define, specify, and coordinate tooling and fixtures, including dies, forming tools, templates, and check fixtures.
• Interface with Tier 1 and Tier 2 suppliers specializing in sheet metal fabrication to ensure alignment on requirements, schedule, cost, quality, and risk.
• Conduct trade studies and resolve technical challenges related to forming feasibility, springback, distortion, and dimensional control.
• Apply machining process knowledge (CNC trimming, drilling, finishing) to support part completion, tolerance achievement, and assembly integration.
• Establish and document manufacturing standards, work instructions, and best practices for sheet metal fabrication and finishing operations.
• Support make vs. buy decisions and supplier selection strategies for metallic components.
• Contribute to the development of a greenfield fabrication capability, including process flow, factory layout, and equipment selection.

What You Bring

• Bachelor's degree in Mechanical, Manufacturing, or Aerospace Engineering, or a related field.
• 8+ years of experience in aerospace manufacturing or production engineering.
• Strong experience with sheet metal fabrication processes, including forming, bending, and trimming.
• Working knowledge of machining processes such as CNC machining, drilling, and finishing operations.
• Solid understanding of GD&T, tolerancing, and dimensional control for formed and machined parts.
• Excellent 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 with aerospace sheet metal structures, including skins, ribs, frames, and brackets.
• Familiarity with forming simulation, springback compensation, and tooling development.
• Background working with aircraft OEMs or Tier 1 suppliers in development and/or production programs.
• Knowledge of special processes such as heat treatment, surface treatments, and chemical milling.
• Experience integrating machined features with formed components in structural assemblies.
• Working knowledge of CAD and PLM tools.

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.

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.