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Salary: USD 219,000 - 273,700 / annual
Archer Technologies, a Silicon Valley-based leader in next-generation aerospace, is seeking a Principal Materials and Processes (M&P) Engineer to serve as the Metallics Subject Matter Expert for the airframe of their next-generation electric vertical takeoff and landing (eVTOL) aircraft. This is a hands-on, high-impact role on a fast-moving certification program.
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. Key responsibilities include:
• Serve as 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.
• Develop compliance data and substantiation for M&P-related airworthiness requirements; interface with the FAA, DERs, and internal certification teams to support certification activities.
• Work closely with stress, design, manufacturing, quality, supply chain, and certification teams to make timely trade-offs that keep the program moving.
• Help build and mature Archer's M&P metallics capability, including lab test methods, processes, tools, and mentorship of junior engineers.
• 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.
• 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.
• 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.
• Define corrosion prevention and control requirements for metallic structure, including galvanic compatibility, dissimilar-material isolation, sealants, and finish systems.
• Support manufacturing and suppliers through material review board (MRB) dispositions, nonconformance resolution, first article inspections (FAI), special-process source approvals, and supplier audits.
• Lead failure analysis and root cause investigations using fractography, metallography, SEM/EDS, and hardness and conductivity testing; drive corrective and preventive actions to closure.
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.
REQUIREMENTS:
• 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.
• 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).
• Strong understanding of heat treatment, microstructure-property relationships, fatigue, fracture mechanics, damage tolerance, stress corrosion cracking, and hydrogen embrittlement.
• Working knowledge of special processes: 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).
• Fluency with MMPDS, SAE AMS, ASTM, MIL, and NAS specifications, as well as galvanic compatibility guidance such as MIL-STD-889.
• Experience with nondestructive testing methods, including dye penetrant (ASTM E1417), magnetic particle (ASTM E1444), ultrasonic, and eddy current, and with defining acceptance criteria.
• 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.
• Hands-on experience with fractography, metallography, and SEM/EDS for root cause analysis; ability to 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 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.
