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Freelance Gear Design Engineer Jobs in Virginia (NOW HIRING)

Electra

Airframe Design Engineer

Manassas, VA

$92K - $112K/yr

The Role Electra is seeking a Airframe Design Engineer to help the design, integration, and ... landing gear integration. * Assist with structural design tasks from concept through detailed ...

HII

ENGINEER MECHANICAL 3

Newport News, VA · On-site

$99K - $122K/yr

ENGINEER MECHANICAL 3 Location: Newport News, Virginia, United States Date: Aug 26, 2026 Req ID ... Technical understanding of turbine-powered main reduction gears (or sub-components), gear design ...

HII

ENGINEER MECHANICAL 3

Newport News, VA · On-site

$99K - $122K/yr

ENGINEER MECHANICAL 3 Location: Newport News, Virginia, United States Date: Aug 26, 2026 Req ID ... Technical understanding of turbine-powered main reduction gears (or sub-components), gear design ...

HII

$99K - $122K/yr

ENGINEER MECHANICAL 3 Location: Newport News, Virginia, United States Date: Aug 26, 2026 Req ID ... Technical understanding of turbine-powered main reduction gears (or sub-components), gear design ...

HII

$99K - $122K/yr

ENGINEER MECHANICAL 3 Location: Newport News, Virginia, United States Date: Aug 26, 2026 Req ID ... Technical understanding of turbine-powered main reduction gears (or sub-components), gear design ...

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Freelance Gear Design Engineer information

What does a freelance gear design engineer do?

A Freelance Gear Design Engineer specializes in designing gears and gear systems for various mechanical applications, such as automotive, industrial machinery, and robotics. They work independently with clients to create precise gear specifications, perform calculations, model gears using CAD software, and ensure the designs meet performance and durability requirements. Their responsibilities also include collaborating with other engineers, providing technical documentation, and sometimes overseeing prototype fabrication or testing. Freelance Gear Design Engineers offer flexibility and expertise to companies needing specialized gear solutions without hiring a full-time engineer.

What are the key skills and qualifications needed to thrive as a freelance gear design engineer, and why are they important?

To thrive as a Freelance Gear Design Engineer, you need a solid background in mechanical engineering, expertise in gear design principles, and experience with CAD software, often supported by a relevant engineering degree. Proficiency with tools like SolidWorks, Autodesk Inventor, and gear calculation software, as well as familiarity with industry standards such as AGMA or ISO, is typically required. Strong project management, client communication, and problem-solving skills help you excel in delivering custom solutions and managing diverse projects independently. These skills are essential for producing precise, reliable designs that meet client specifications and industry standards in a competitive freelance environment.

What are some common challenges freelance gear design engineers face when collaborating with clients remotely?

Freelance gear design engineers often encounter challenges such as aligning on technical requirements, managing communication across time zones, and ensuring secure exchange of proprietary design files. It’s important to establish clear project milestones, use reliable collaboration tools for sharing CAD models, and maintain regular check-ins with clients to address feedback promptly. Building strong documentation habits and proactively clarifying expectations can help smooth the remote collaboration process and lead to successful project outcomes.

What is the difference between Freelance Gear Design Engineer vs Mechanical Gear Designer?

AspectFreelance Gear Design EngineerMechanical Gear Designer
CredentialsRelevant engineering degrees, certifications often freelance or self-taughtTypically holds a degree in mechanical engineering, with specialized gear design certifications
Work EnvironmentIndependent, project-based, remote or on-siteEmployed by companies, design departments, or manufacturing firms
Industry UsageFreelance consulting, custom projects, small businessesIn-house design teams, manufacturing, industrial sectors
Search & Comparison IntentLooking for freelance gear design services or contractorsSeeking in-house or full-time gear design roles

In summary, a Freelance Gear Design Engineer works independently on custom projects, often remotely, while a Mechanical Gear Designer is typically employed full-time within a company’s design team. Both roles require engineering knowledge, but their work settings and employment types differ significantly.

What are the most commonly searched types of Gear Design Engineer jobs in Virginia?

The most popular types of Gear Design Engineer jobs in Virginia are:

What cities in Virginia are hiring for Freelance Gear Design Engineer jobs?

Cities in Virginia with the most Freelance Gear Design Engineer job openings:

Freelance Gear Design Engineer jobs near you

Airframe Design Engineer

Electra

Manassas, VA

$92K - $112K/yr

Full-time

Medical, Dental, Vision, Life, Retirement, PTO

Re-posted 16 days ago

Key responsibilities

  • Support the design and development of primary and secondary airframe structures, including fuselage, wing, empennage, and landing gear integration.

  • Assist with structural design tasks from concept through detailed design and into certification, ensuring compliance with performance, manufacturability, and safety requirements.

  • Collaborate with multidisciplinary teams and work with structural requirements, material selections, and design criteria to ensure integrated and optimized structural solutions.

Job description

About Electra

At Electra, we're building the EL9 — a nine-passenger, hybrid-electric aircraft that takes off and lands in 150 feet. Our Ultra Short technology unlocks thousands of new operating locations and enables what we call Direct Aviation: quiet, point-to-point regional travel that gets people from where they are to where they want to go, without the congestion of major airports or the noise of conventional aviation.

A global company, headquartered in Manassas, VA, Electra is backed by Lockheed Martin, Honeywell, and Safran, has filed for FAA Part 23 type certification, and carries 2,000+ intent to purchase from operators worldwide. We're a team of ~100 people moving fast toward first EL9 test flights in 2027 and certification by late 2029 or 2030. Every hire matters at this stage — and this role is no exception.

The Role

Electra is seeking a Airframe Design Engineer to help the design, integration, and development of primary and secondary structures for our nine-passenger EL9 hybrid-electric aircraft.

In this role, you will support 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.

This role is based at our Manassas, VA headquarters, with on-site presence strongly preferred, and includes occasional travel (under 10%).

What You'll Do

  • Support the design and development of primary and secondary airframe structures, including fuselage, wing, empennage, and landing gear integration.
  • Assist with structural design tasks from concept through detailed design and into certification, ensuring compliance with performance, manufacturability, maintainability, and safety requirements.
  • Work with 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
  • Support CAD admin duties such as tool and process development for designers

What You Bring

  • Bachelor's degree in Aerospace Engineering, Mechanical Engineering, or related field; Master's degree preferred
  • 2+ years of experience in aircraft structural or airframe design, integration, and development (or equivalent combination of education and experience)
  • 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

Bonus Points

  • 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

This range reflects the anticipated hiring range across all eligible locations; actual compensation is determined based on your relevant experience, skills, and geographic location. Total compensation includes performance bonus and comprehensive benefits.

Compensation Range
$92,000—$112,000 USD

What We Offer

  • Competitive salary and equity
  • Medical, dental, and vision insurance; STD, LTD, and life insurance
  • Generous PTO, sick leave, and company holidays
  • Paid winter break
  • 401(k) with immediate vesting
  • Free catered lunches, coffee, snacks, and drinks at our Manassas headquarters
  • Free on-site parking

Electra is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, disability, veteran status, or any other characteristic protected by law. This position may be subject to ITAR requirements.