Lead Experimental Design, Manufacturing Engineer

Supernal - Irvine, CA

Full-time - Mid Level

Irvine, CA

Transportation Equipment Manufacturing

About the position

The Lead Experimental Design, Manufacturing Engineer at Supernal plays a pivotal role in the development of an electric vertical take-off and landing (eVTOL) vehicle and its supporting ecosystem. This position is integral to the Test, Evaluation, and Certification (TEC) Team, focusing on the manufacturing aspects of the project. The engineer will be responsible for creating efficient manufacturing solutions and processes that support the testing and prototype development of the eVTOL system. This role requires a collaborative approach, working closely with both internal teams and external partners to ensure that the manufacturing processes align with the overall project goals and safety standards. In this position, the Lead Experimental Design, Manufacturing Engineer will oversee manufacturing operations, providing critical feedback to leadership regarding technical approaches, products, and processes. The engineer will also be tasked with developing and maintaining standard processes and procedures, ensuring that they are effectively implemented throughout the design phases, from conceptual to detailed design. A significant part of the role involves hands-on manufacturing and assembly of prototype and flight test aircraft, as well as the installation of test instrumentation systems necessary for data collection during testing. The engineer will lead various manufacturing activities, including vendor trade studies, design for manufacturability (DFM) assessments, and the coordination of procurement and integration efforts. They will also document manufacturing processes and work instructions, support aircraft installation and integration, and prepare technical materials for communication with management and team members. This position requires a proactive approach to problem-solving and the ability to prioritize tasks effectively to meet tight timelines. Additionally, the role involves up to 25% travel, both domestically and internationally, to support manufacturing and testing activities.

Responsibilities

• Lead all aspects of manufacturing and vendor trade studies
• Provide manufacturing support for Tests with an emphasis on speed and efficiency
• Coordinate manufacturing development activities, including DFM assessment, design reviews, procurement, and installation/integration
• Run test fixture manufacturing activities
• Run prototype manufacturing activities
• Provide technical guidance and oversight to suppliers as well as design support
• Craft CNC machining, additive manufacturing, and sheet metal components
• Assist TEC Leadership in prioritizing efforts based on manufacturing timelines
• Document manufacturing process and work instructions
• Support aircraft installation and integration, including writing and releasing engineering orders and functional test procedures required for flight test and production aircraft
• Prepare and communicate design and technical materials to management and team members
• Partner with all other groups within the TEC organization to support test execution

Requirements

• Bachelor's degree in mechanical or related engineering field required; Master's or Ph.D. degree preferred
• Minimum ten (10) years of experience with manufacturing or design of an aerospace system/product development (an equivalent combination of education and experience may be considered)
• Experience leading a technical team
• Experience developing and implementing new processes and procedures
• Experience with new aircraft development, prototyping, certification, and production
• Experience with supplier management and evaluation in a manufacturing capacity
• Experience with the assembly and testing of prototype aircraft
• Knowledge of ASME Y14.5 GD&T
• Knowledge of certification rules and processes, including ARP 4754A, ARP 4761, DO-160
• Excellent verbal and written communication skills
• Proactive delivery of communication and follow up
• Excellent organizational skills and attention to detail
• Must have the ability to independently prioritize and accomplish work within time constraints
• Proficiency with Excel VLOOKUP, pivot tables, MS Office Suite

Nice-to-haves

• Experience in Aerospace Test and Evaluation preferred
• Experience testing one or more of the following is preferred: Avionics, Aircraft Powertrain, Energy Storage Systems, Flight Controls, Aircraft Performance, Airframe Structures
• Experience leading a team of technical personnel is preferred
• CATIA Experience preferred

Benefits

• Base pay offered may vary depending on skills, experience, job-related knowledge and location
• Eligible for a bonus as part of total compensation