Principal Materials and Processes Engineer - Metallics

We are seeking an experienced Materials and Processes (M&P) Engineer to serve as the Metallics Subject Matter Expert (SME) for the airframe of our next-generation electric vertical takeoff and landing (eVTOL) aircraft, being certified under FAA airworthiness criteria derived from 14 CFR Part 23 eVTOL aircraft and Part 21.17(b) powered-lift.

In this role, you will be the technical authority for metallic materials and processes across primary and secondary airframe structure, from alloy selection and specification development through qualification, production support, and FAA certification.

This is a hands-on role on a fast-moving program. The ideal candidate brings deep metallurgical expertise, a strong command of aerospace specifications and certification requirements, and the judgment to make sound, timely decisions with incomplete information. You will thrive here if you bring a flexible mindset, a strong sense of urgency, and the ability to create structure and clarity in an ambiguous, rapidly evolving environment. We are looking for individuals who are slightly impatient, flexible under changing priorities and perform under pressure.

What you’ll do

• Technical authority: Serve as the M&P Metallics SME; owning metallic material and process decisions for aluminum, titanium, steel, and corrosion-resistant alloys used in structure, engine, battery components, fittings, and fasteners.
• Certification: Develop compliance data and substantiation for M&P-related airworthiness requirements, and interface with the FAA, DERs, and internal certification teams to support certification activities. Develop, author, review internal MPE specs, test plans, other specs.
• Cross-functional partnership: Work closely with stress, design, manufacturing, quality, supply chain, and certification teams to make timely trade-offs that keep the program moving.
• Build the function: Help build and mature Archer’s M&P metallics capability, including lab test methods, processes, tools, and mentorship of junior engineers.
• Qualification and allowables: Plan and execute metallic material and process qualification programs, including test plans, test matrices, conformity, data review, and reports; establish material strength properties and design values using MMPDS and statistically based methods.
• Specifications and design guidance: Author and maintain Archer material and process specifications, design guidelines, and standards, including heat treatment, surface treatment, plating, shot peening, welding/joining, machining, and inspection requirements.
• Material selection: Lead alloy, temper, and product-form selection (plate, sheet, extrusion, forging, casting, bar, and additively manufactured parts), balancing strength, fatigue and damage tolerance, corrosion resistance, weight, cost, and manufacturability.
• Corrosion control: Define corrosion prevention and control requirements for metallic structure, including galvanic compatibility, dissimilar-material isolation (including metal-to-composite interfaces), sealants, and finish systems.
• Production and supplier support: Support manufacturing and suppliers through material review board (MRB) dispositions, nonconformance resolution, first article inspections (FAI), special-process source approvals, and supplier audits (including NADCAP-accredited and not accredited processes).
• Failure analysis: Lead failure analysis and root cause investigations using fractography, metallography, SEM/EDS, and hardness and conductivity testing, and drive corrective and preventive actions to closure.

What you’ll need

• Bachelor’s degree in Metallurgical Engineering, Materials Science and Engineering, Mechanical Engineering, or a related field; Master’s or PhD preferred.
• Minimum 8 years of aerospace M&P experience focused on metallic materials and processes (6 years with an advanced degree), including direct support of metallic structures.
• Demonstrated track record leading material and process qualification, specification development, and FAA (or equivalent EASA/military) certification activities.
• Aerospace alloys: In-depth knowledge of aerospace aluminum (2xxx, 6xxx, 7xxx series and tempers), titanium (e.g., Ti-6Al-4V), precipitation-hardening and corrosion-resistant steels (e.g., 15-5PH, 17-4PH, A286, 440C, 314), and low-alloy steels (e.g., 4130, 4340, 300M).
• Physical metallurgy: Strong understanding of heat treatment, microstructure-property relationships, fatigue, fracture mechanics, damage tolerance, stress corrosion cracking, and hydrogen embrittlement.
• Special processes: Working knowledge of heat treatment (e.g., AMS 2770, AMS 2759), anodizing and conversion coating (e.g., MIL-PRF-8625, MIL-DTL-5541), passivation (AMS 2700), plating, shot peening (AMS 2430/AMS 2432), and welding/joining (e.g., AWS D17.1).
• Standards and data: Fluency with MMPDS, SAE AMS, ASTM, MIL, and NAS specifications, as well as galvanic compatibility guidance such as MIL-STD-889.
• Inspection and NDT: Experience with nondestructive testing methods, including dye penetrant (ASTM E1417), magnetic particle (ASTM E1444), ultrasonic, and eddy current, and with defining acceptance criteria.
• Regulatory knowledge: Familiarity with FAA regulations, Advisory Circulars, and M&P-related airworthiness requirements, including material and process control, fabrication methods, and material strength properties and design values.
• Failure analysis: Hands-on experience with fractography, metallography, and SEM/EDS for root cause analysis. Define metallic F&DT methodology (slow crack growth, safe-life) in coordination with structures team

Preferred qualifications

• Experience on a new aircraft development and type certification program, ideally in eVTOL, general aviation, or rotorcraft.
• Experience with forgings and castings, including casting factors and classification (e.g., AMS 2175).
• Experience with metallic–composite hybrid structures, fastener systems, and bonded or sealed joints.
• Experience with conducting supplier audits, establishing or approving NADCAP-accredited special processes, AS9100 quality management system
• FAA DER or Designee experience, or experience working directly with Designees and FAA Aircraft Certification Offices.

*Please note that this job description is intended to provide a general overview of the position and does not include an exhaustive list of responsibilities and qualifications

At Archer we aim to attract, retain, and motivate talent that possess the skills and leadership necessary to grow our business. We drive a pay-for-performance culture and reward performance that supports the Company’s business strategy. For this position we are targeting a base pay between $219,000- $273,700 . Actual compensation offered will be determined by factors such as job-related knowledge, skills, and experience.

Archer is committed to working with and providing reasonable accommodations to job applicants with physical or mental disabilities, and those with sincerely held religious beliefs. Applicants who may require reasonable accommodation for any part of the application or hiring process should provide their name and contact information to Archer’s People Team at [email protected]. Reasonable accommodations will be determined on a case-by-case basis.