Senior Manufacturing Engineer

About ZeroAvia

ZeroAvia is advancing the shift towards emission-free aviation by creating and certifying hydrogen-electric propulsion solutions. Their technology integrates hydrogen fuel cells, electric motors, advanced electronics, and aerospace-level systems integration to enable a new generation of clean aircraft.

Role Overview

We are looking for a Senior Manufacturing Engineer to spearhead manufacturing development in a fast-moving, prototype-centered setting. This role demands a practical engineer who excels in an environment with frequent design changes, tight build schedules, and close collaboration with engineering teams. This pivotal role will facilitate the transition from concept designs and prototypes to low-rate production and fully certified aerospace products by bridging design engineering and production.

Key Responsibilities

• Oversee manufacturing efforts across prototype, development, and certification programs to support system integration, testing, and flight-test activities, while resolving manufacturing issues promptly.
• Create, validate, and refine manufacturing processes, assembly methods, and related documentation to ensure safe, efficient, and scalable production of sophisticated aerospace systems.
• Serve as manufacturing lead within product development teams, applying Design for Manufacture and Assembly (DFMA) principles to enhance quality, reduce costs, and improve manufacturability and performance.
• Drive industrialization and production readiness efforts, including developing manufacturing strategies, specifying tooling and equipment, validating processes, and planning capacity to facilitate the move from development to serial production.
• Ensure adherence to aerospace quality and regulatory standards by supporting process qualifications, first article inspections, audits, root cause analyses, and certification activities.
• Lead initiatives for continuous improvement by collaborating with Engineering, Quality, Supply Chain, and Production teams to boost productivity, minimize waste, improve build quality, and meet strategic manufacturing goals.

Candidate Requirements

• Bachelor’s degree in Manufacturing, Mechanical, Aerospace, Industrial Engineering, or a related field plus at least 7 years of manufacturing engineering experience in aerospace, defense, motorsport, advanced energy, or similarly regulated industries.
• Expertise in supporting prototype and development projects by launching new products from concept to production and developing manufacturing processes for complex electro-mechanical assemblies.
• Comprehensive knowledge of aerospace manufacturing, including assembly techniques, precision machining, process validation, configuration management, engineering change management, and designing production tooling and fixtures.
• Capability to interpret engineering drawings, CAD models, specifications, and bills of materials and familiarity with ERP/MRP systems and manufacturing planning tools.
• Experience with aerospace quality and certification standards, preferably AS9100 and Part 21, plus advantageous knowledge of hydrogen fuel cells, electric propulsion, battery systems, or power electronics technologies.
• Strong problem-solving, communication, and stakeholder management abilities, with a proactive mindset and adaptability to thrive in a rapidly evolving, high-growth engineering environment.

Employee Benefits

• Comprehensive private health and dental insurance with family coverage options.
• Robust mental health support including trained Mental Health First Aiders and Employee Assistance Programs.
• Complimentary lunches and nutritious snacks to keep teams energized.
• Opportunities for involvement in sports, games, and cultural clubs such as running, cycling, padel, trivia, theatre, and gardening.
• Stock options shared among employees.
• 25 days of annual leave plus public holidays and extra service-related leave days to support work-life balance.
• Free electric vehicle charging and participation in an EV Club.
• Salary sacrifice schemes for EV Club, tech purchases, and cycling to work.
• Weekly performance bonuses to acknowledge excellence.
• Income protection and legal support services.
• Relocation assistance to facilitate a smooth transition to the role.

Diversity and Inclusion

We actively cultivate diversity as a catalyst for innovation and growth. ZeroAvia is committed to equal opportunities and embraces all individuals regardless of race, religion, color, national origin, sex, gender identity, sexual orientation, age, marital status, veteran status, or disability.