We are seeking a motivated Manufacturing Engineer with a strong background in advanced manufacturing and special processes. This role supports production and engineering teams in developing, validating, and optimising manufacturing methods with a primary focus on machining, metal fabrication, and related special processes. The successful candidate will also contribute to the development, implementation, and control of special processes whose outputs cannot be fully verified by inspection, such as welding, composites, electronics assembly, and additive manufacturing, ensuring compliance with AS9100, NADCAP, and relevant regulatory bodies. Key Responsibilities:<ul><li>Develop, execute, and maintain CNC machining and fabrication processes, including forming, bending, rolling, and stamping, ensuring compliance with aerospace standards and using CAD/CAM software in compliance with AS9100, NADCAP, and ZeroAvia quality policies.</li><li>Specify tooling, fixtures, and CNC machine setups for prototype and production runs.</li><li>Lead and participate in the qualification, implementation, and monitoring of special processes, ensuring full control plans and process documentation are developed and maintained.</li><li>Support qualification testing and process validation activities with internal quality teams and external regulators.</li><li>Collaborate with Quality and Supply Chain teams to ensure process capability, supplier qualification, and continued compliance.</li><li>Develop and maintain controlled work instructions, process documentation, and inspection plans aligned with aerospace standards.</li><li>Support New Product Introduction (NPI) by translating designs into manufacturable processes, including DFM/DFA analysis.</li><li>Drive root cause analysis, FMEA, and corrective actions for process deviations and non-conformances.</li><li>Apply Lean and continuous improvement methodologies to improve process capability and reduce variation.</li><li>Work cross-functionally with design, production, and quality teams to resolve day-to-day manufacturing challenges.</li><li>Demonstrate a strong safety and quality mindset in all operations.</li></ul>Requirements<ul><li>Degree in Mechanical, Manufacturing, or Production Engineering or equivalent.</li><li>5+ years’ experience in manufacturing within aviation, aerospace, or a similarly regulated industry.</li><li>Hands-on expertise with CNC machining, tooling, forming, and fabrication processes.</li><li>Experience in qualifying and controlling special processes (welding, additive, composites, electronics).</li><li>Experience working with regulatory authorities (AS9100, NADCAP, CAA/EASA/FAA).</li><li>Strong proficiency in CAD/CAM tools (e.g., SolidWorks, Siemens NX) and familiarity with PLM (Teamcenter), MES, and ERP systems.</li><li>Strong understanding of engineering drawings, GD&amp;T, and aerospace quality standards.</li><li>Practical experience in tooling design, fixture development, and process documentation.</li><li>Familiarity with Lean manufacturing, 5S, and continuous improvement.</li><li>Strong problem solving, collaboration, and communication skills across technical and management teams.</li></ul>BenefitsWhy Join Us? We want to help you be your best self, at work and at home, that’s why we provide our employees with… <ul><li>Private health and dental care – get access to services and support when you need them. Add your family members too* </li></ul><ul><li>Mental health support – enjoy a culture where positive mental health is front of mind with our trained Mental Health First Aiders, Employee Assistance Programmes and wellbeing support. </li><li>Free lunch and healthy snacks – keeping you fueled up so you can help us deliver the technology of the future** </li><li>Sports, games and culture clubs – connect and keep fit with other ZeroAvians by joining one of our subsidised clubs – such as, running, cycling, padel, trivia, theatre and gardening. </li></ul>We also offer:  <ul><li>Stock options – so youcan share in our success. </li><li>5 hours of free flying lessons  </li><li>25 days holiday, plus public holidays – to help you manage your work-life balance. </li><li>Free EV Charging and membership in our EV Club. </li><li>Salary Sacrifice Schemes for EV Club, Curry's Tech, Cycle to Work, and Ikea Furniture. </li><li>Weekly Spot Bonuses to reward excellence. </li><li>Income Protection and Legal Support for peace of mind. </li><li>Relocation Support to make your move seamless.</li></ul><h3>Diversity and Inclusion</h3>As an emergent company shaping the aviation industry, we know that diversity fuels success and unlocks potential. We embrace being an equal-opportunity employer and actively seek individuals from diverse backgrounds. We value the multitude of skills, perspectives, and mindsets everyone can bring to the table. These experiences ignite creativity, originality, and growth. We proudly reject discrimination in all forms, including that based on race, religion, color, national origin, sex, gender expression, sexual orientation, age, marital status, veteran status, or disability status.

ZeroAvia enables zero emission air travel at scale, starting with 500 mile short-haul trips, at half of today’s cost.

Senior Process Manufacturing Engineer

We are seeking a motivated Manufacturing Engineer with a strong background in advanced manufacturing and special processes. This role supports production and engineering teams in developing, validating, and optimising manufacturing methods with a primary focus on machining, metal fabrication, and related special processes. The successful candidate will also contribute to the development, implementation, and control of special processes whose outputs cannot be fully verified by inspection, such as welding, composites, electronics assembly, and additive manufacturing, ensuring compliance with AS9100, NADCAP, and relevant regulatory bodies.&nbsp;Key Responsibilities:<ul><li>Develop, execute, and maintain CNC machining and fabrication processes, including forming, bending, rolling, and stamping, ensuring compliance with aerospace standards and using CAD/CAM software in compliance with AS9100, NADCAP, and ZeroAvia quality policies.</li><li>Specify tooling, fixtures, and CNC machine setups for prototype and production runs.</li><li>Lead and participate in the qualification, implementation, and monitoring of special processes, ensuring full control plans and process documentation are developed and maintained.</li><li>Support qualification testing and process validation activities with internal quality teams and external regulators.</li><li>Collaborate with Quality and Supply Chain teams to ensure process capability, supplier qualification, and continued compliance.</li><li>Develop and maintain controlled work instructions, process documentation, and inspection plans aligned with aerospace standards.</li><li>Support New Product Introduction (NPI) by translating designs into manufacturable processes, including DFM/DFA analysis.</li><li>Drive root cause analysis, FMEA, and corrective actions for process deviations and non-conformances.</li><li>Apply Lean and continuous improvement methodologies to improve process capability and reduce variation.</li><li>Work cross-functionally with design, production, and quality teams to resolve day-to-day manufacturing challenges.</li><li>Demonstrate a strong safety and quality mindset in all operations.</li></ul>Requirements<ul><li>Degree in Mechanical, Manufacturing, or Production Engineering or equivalent.</li><li>5+ years’ experience in manufacturing within aviation, aerospace, or a similarly regulated industry.</li><li>Hands-on expertise with CNC machining, tooling, forming, and fabrication processes.</li><li>Experience in qualifying and controlling special processes (welding, additive, composites, electronics).</li><li>Experience working with regulatory authorities (AS9100, NADCAP, CAA/EASA/FAA).</li><li>Strong proficiency in CAD/CAM tools (e.g., SolidWorks, Siemens NX) and familiarity with PLM (Teamcenter), MES, and ERP systems.</li><li>Strong understanding of engineering drawings, GD&amp;T, and aerospace quality standards.</li><li>Practical experience in tooling design, fixture development, and process documentation.</li><li>Familiarity with Lean manufacturing, 5S, and continuous improvement.</li><li>Strong problem solving, collaboration, and communication skills across technical and management teams.</li></ul>BenefitsWhy Join Us?&nbsp;We want to help you be your best self, at work and at home, that’s why we provide our employees with…&nbsp;<ul><li>Private health and dental care&nbsp;– get access to services and support when you need them. Add your family members too*&nbsp;</li></ul><ul><li>Mental health support&nbsp;– enjoy a culture where positive mental health is front of mind with our trained Mental Health First Aiders, Employee Assistance Programmes and wellbeing support.&nbsp;</li><li>Free lunch and healthy snacks&nbsp;– keeping you fueled up so you can help us deliver the technology of the future**&nbsp;</li><li>Sports, games and culture clubs&nbsp;– connect and keep fit with other ZeroAvians by joining one of our subsidised clubs – such as, running, cycling, padel, trivia, theatre and gardening.&nbsp;</li></ul>We also offer:&nbsp;&nbsp;<ul><li>Stock options&nbsp;– so youcan share in our success.&nbsp;</li><li>5 hours&nbsp;of free&nbsp;flying lessons&nbsp;&nbsp;</li><li>25 days holiday, plus public holidays&nbsp;– to help you manage your work-life balance.&nbsp;</li><li>Free EV Charging&nbsp;and membership in our EV Club.&nbsp;</li><li>Salary Sacrifice Schemes&nbsp;for EV Club, Curry's Tech, Cycle to Work, and Ikea Furniture.&nbsp;</li><li>Weekly Spot Bonuses&nbsp;to reward excellence.&nbsp;</li><li>Income Protection and Legal Support&nbsp;for peace of mind.&nbsp;</li><li>Relocation Support&nbsp;to make your move seamless.</li></ul><h3>Diversity and Inclusion</h3>As an emergent company shaping the aviation industry, we know that diversity fuels success and unlocks potential. We embrace being an equal-opportunity employer and actively seek individuals from diverse backgrounds. We value the multitude of skills, perspectives, and mindsets everyone can bring to the table. These experiences ignite creativity, originality, and growth. We proudly reject discrimination in all forms, including that based on race, religion, color, national origin, sex, gender expression, sexual orientation, age, marital status, veteran status, or disability status.

Senior Process Manufacturing Engineer

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ZeroAvia

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