Thanks for the info and the advice. I know my PhD isn't going to help me, at least not directly, because it's only peripherally related but my undergrad background is very solid. I've also interned at Rolls-Royce working on jet engines, and I know the kind of materials design issues they'll be running up against. e.g. in the article he mentions stir welding, something I've studied (and had the pleasure of visiting the organisation that developed it, TWI). So while I don't have actual "hands-on" experience building stuff that flies, I still think I could be useful.

Dude go for it! Sounds like the opportunity of a life time and you sound like you know your stuff. Send some emails!