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Additive Manufacturing Design Engineer Jobs in Washington

Electra

Senior Airframe Design Engineer

Manassas, VA · On-site

$100K - $136K/yr

Senior Airframe Design Engineer About Electra At Electra, we're pioneering sustainable aviation ... Collaborate with aerodynamics, propulsion, systems, manufacturing, stress, and certification teams ...

Mainstream Engineering

Senior Thermal Engineer

Alexandria, VA · On-site

$101K - $134K/yr

... and design for manufacture. Individual engineers lead their own projects and research. Your ... additive manufacturing, membrane enhanced cooling, oscillating heat pipes. This position includes ...

Mainstream Engineering

Senior Thermal Engineer

Alexandria, VA · On-site

$101K - $134K/yr

... and design for manufacture. Individual engineers lead their own projects and research. Your ... additive manufacturing, membrane enhanced cooling, oscillating heat pipes. This position includes ...

Leidos

Senior Mechanical Engineer

Sterling, VA · On-site

$107K - $195K/yr

We are seeking a Senior Mechanical Engineer for a lead position in the design, development and ... additive manufacturing techniques Strong experience with design for assembly and production ...

Leidos

Senior Mechanical Engineer

Sterling, VA · On-site

$107K - $195K/yr

We are seeking a Senior Mechanical Engineer for a lead position in the design, development and ... additive manufacturing techniques Strong experience with design for assembly and production ...

Cymertek

Hardware Design Engineer

Tysons, VA · On-site

Hardware Design Engineer LOCATIONTysons, VA 22182 CLEARANCETS/SCI Full Poly (Please note this ... Proficiency with design for manufacturability (DFM) * Knowledge of signal integrity and RF design

Cymertek

Hardware Design Engineer

Chantilly, VA · On-site

Hardware Design Engineer LOCATIONChantilly, VA 20151 CLEARANCETS/SCI Full Poly (Please note this ... Proficiency with design for manufacturability (DFM) * Knowledge of signal integrity and RF design

Cymertek

Hardware Design Engineer

Reston, VA · On-site

Hardware Design Engineer LOCATIONReston, VA 20190 CLEARANCETS/SCI Full Poly (Please note this ... Proficiency with design for manufacturability (DFM) * Knowledge of signal integrity and RF design

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All JobsAdditive Manufacturing Design Engineer JobsAdditive Manufacturing Design Engineer Jobs in Washington

Additive Manufacturing Design Engineer information

See Washington salary details

$51.5K

$97.6K

$154K

How much do additive manufacturing design engineer jobs pay per year?

As of Jun 9, 2026, the average yearly pay for additive manufacturing design engineer in Washington is $97,572.00, according to ZipRecruiter salary data. Most workers in this role earn between $79,300.00 and $113,300.00 per year, depending on experience, location, and employer.

What are the key skills and qualifications needed to thrive as an Additive Manufacturing Design Engineer, and why are they important?

To thrive as an Additive Manufacturing Design Engineer, you need a solid background in mechanical engineering, CAD modeling, and materials science, typically supported by a relevant engineering degree. Expertise in 3D modeling software (such as SolidWorks or Autodesk Fusion 360), familiarity with additive manufacturing systems, and knowledge of relevant industry standards or certifications (like ASME or ASTM) are crucial. Strong problem-solving abilities, creativity, and effective communication skills help you innovate and collaborate across multidisciplinary teams. These competencies are vital for developing manufacturable, cost-effective designs and driving innovation in a rapidly evolving field.

What does an Additive Manufacturing Design Engineer do?

An Additive Manufacturing Design Engineer specializes in designing products and components specifically for 3D printing and other additive manufacturing processes. They use advanced CAD software to create models optimized for material usage, strength, and manufacturability. Their role often involves collaborating with engineers, manufacturers, and clients to ensure that designs meet technical requirements and take full advantage of additive manufacturing capabilities. This includes selecting appropriate materials, adjusting designs for printability, and troubleshooting issues during prototyping and production.

What are some common challenges an Additive Manufacturing Design Engineer faces when collaborating with cross-functional teams?

Additive Manufacturing Design Engineers often work closely with teams from R&D, production, and quality assurance, which can present challenges such as aligning design intent with manufacturability constraints and ensuring clear communication about technical requirements. Differences in understanding additive manufacturing capabilities may require the engineer to provide education or guidance to colleagues from traditional manufacturing backgrounds. Effective collaboration involves regularly sharing progress, addressing feedback efficiently, and adapting designs based on input from multiple disciplines to achieve optimal part performance and cost efficiency.

What is the difference between Additive Manufacturing Design Engineer vs Mechanical Design Engineer?

AspectAdditive Manufacturing Design EngineerMechanical Design Engineer
Required CredentialsBachelor's in Mechanical, Manufacturing, or related engineering; CAD certificationsBachelor's in Mechanical or Aerospace Engineering; CAD certifications
Work EnvironmentDesign labs, manufacturing facilities, 3D printing environmentsDesign offices, manufacturing plants, R&D labs
Industry UsagePrimarily in additive manufacturing, aerospace, automotive, healthcareBroadly in product design, machinery, automotive, aerospace

The Additive Manufacturing Design Engineer specializes in designing parts specifically for 3D printing and additive processes, focusing on material properties and printability. In contrast, the Mechanical Design Engineer works on a wider range of mechanical systems and components, often using traditional manufacturing methods. Both roles require strong CAD skills and engineering knowledge, but their focus areas and applications differ significantly.

What cities in Washington are hiring for Additive Manufacturing Design Engineer jobs? Cities in Washington with the most Additive Manufacturing Design Engineer job openings:
Senior Airframe Design Engineer

Senior Airframe Design Engineer

Electra

Manassas, VA • On-site

$100K - $136K/yr

Full-time

Posted 15 days ago

Job description

Senior Airframe Design Engineer
About Electra
At Electra, we're pioneering sustainable aviation through the development of hybrid-electric Ultra Short Takeoff and Landing (eSTOL) aircraft designed to transform regional mobility. Our aircraft operate from soccer-field-sized spaces-enabling Direct Aviation, a new mode of point-to-point air travel that brings communities closer together. Headquartered in Northern Virginia with a location in Switzerland, Electra is building a diverse global team passionate about redefining the future of flight.
Position Overview
Electra is seeking a Senior Airframe Design Engineer to lead key aspects of the design, integration, and development of primary and secondary structures for our nine-passenger EL9 hybrid-electric aircraft.
In this role, you will take ownership of major structural design deliverables, collaborate deeply with multidisciplinary teams, and help ensure the aircraft's structures meet performance, safety, manufacturability, and certification goals. This position is ideal for an experienced engineer ready to contribute at a high level while influencing design decisions across multiple aircraft systems.
Key Responsibilities & Essential Functions
  • Lead the design and development of primary and secondary airframe structures, including fuselage, wing, empennage, and landing gear integration.
  • Own structural design tasks from concept through detailed design and into certification, ensuring compliance with performance, manufacturability, maintainability, and safety requirements.
  • Develop and define structural requirements, material selections, and design criteria in support of applicable airworthiness regulations.
  • Collaborate with aerodynamics, propulsion, systems, manufacturing, stress, and certification teams to ensure integrated and optimized structural solutions.
  • Produce high-quality design documentation, including 3D CAD models, engineering drawings, ICDs, and supporting design reports.
  • Execute trade studies evaluating materials, configurations, manufacturing approaches, and integration options to balance weight, cost, and performance.
  • Support structural analysis activities by working closely with stress engineers on static, dynamic, and fatigue considerations.
  • Participate in design reviews and provide technical mentorship to early-career engineers.
  • Work with suppliers on manufacturability, design-for-production, and technical issue resolution.
  • Contribute to continuous improvement in Electra's structural design methods, tools, and development processes.
  • Stay informed on emerging technologies, advanced materials, and evolving FAA certification requirements for new aircraft types.
Required Education and Experience
  • Bachelor's degree in Aerospace Engineering, Mechanical Engineering, or related field; Master's degree preferred.
  • 8+ years of experience in aircraft structural or airframe design, integration, and development (or equivalent combination of education and experience).
Required Skills and Qualifications
  • Strong understanding of airframe structural design for both metallic and composite components.
  • Demonstrated experience across conceptual, preliminary, and detailed design phases.
  • Proficiency with 3D CAD tools (preferably Siemens NX or CATIA V5/V6).
  • Familiarity with FAA Part 23 or Part 25 structural certification requirements.
  • Working knowledge of loads, stress, and fatigue principles and their influence on design decisions.
  • Experience creating aerospace engineering drawings, design documentation, and configuration-controlled deliverables.
  • Strong communication and collaboration skills for effective cross-functional teamwork.
  • Ability to manage design tasks, priorities, and deadlines in a fast-paced development environment.
Desired Skills and Qualifications
  • Experience with hybrid-electric, eSTOL/eVTOL, or other advanced aircraft development programs.
  • Familiarity with composite manufacturing processes such as AFP, infusion, or hand layup.
  • Experience with FEM tools (NASTRAN, FEMAP, HyperMesh).
  • Background in weight optimization, design-for-manufacturability, or design-to-cost.
  • Knowledge of requirements management or PLM tools (JAMA, Teamcenter, etc.).
  • Experience coordinating with suppliers on design, fabrication, or integration activities.
  • Private pilot license or a strong passion for aviation is a plus.
Location & Additional Information
  • Location: Manassas, VA headquarters (on-site presence strongly preferred).
  • Travel: Occasional (<10%).

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