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Gear Design Jobs in Virginia (NOW HIRING)

Electra

Airframe Design Engineer

Manassas, VA · On-site

$92K - $112K/yr

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 ...

Electra

Airframe Design Engineer

Manassas, VA · On-site

$92K - $112K/yr

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 ...

Electra Aero, Inc.

Airframe Design Engineer

Manassas, VA

$92K - $112K/yr

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 ...

Electra

Senior Airframe Design Engineer

Manassas, VA · On-site

$100K - $136K/yr

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 ...

Electra

Senior Airframe Design Engineer

Manassas, VA · On-site

$100K - $136K/yr

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 ...

BAE Systems

Eng Prin - Elec

Chantilly, VA · On-site

$118K - $200K/yr

Apply innovative design techniques to create cutting-edge electronic systems. * Work in a fast ... May occasionally work in production work centers where use of protective equipment and gear is ...

VIcom

Be Seen First

Project Manager of UCC/IT

Mechanicsville, VA · On-site

$75K - $95K/yr

Design and maintain technical and project documentation * Confirm product ordering with Purchasing team for projects as well as other requirements (gear, lifts, scaffolds, etc.) * Handle new install ...

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All JobsGear Design JobsGear Design Jobs in Virginia

Gear Design information

See Virginia salary details

$21.4K

$83.3K

$149.8K

How much do gear design jobs pay per year?

As of Jul 28, 2026, the average yearly pay for gear design in Virginia is $83,314.00, according to ZipRecruiter salary data. Most workers in this role earn between $53,975.00 and $105,519.00 per year, depending on experience, location, and employer.

What are the key skills and qualifications needed to thrive in the Gear Design position, and why are they important?

To thrive in Gear Design, you need a strong background in mechanical engineering, sound knowledge of gear theory, materials science, and CAD proficiency, often supported by a relevant engineering degree. Familiarity with design software like SolidWorks or CATIA, and analysis tools such as ANSYS or KISSsoft, as well as industry certifications, are commonly expected. Excellent problem-solving abilities, attention to detail, and effective teamwork and communication skills are essential soft skills in this field. These qualifications are critical to ensure the development of precise, reliable, and cost-effective gear systems that meet industry standards and performance requirements.

What is a Gear Design job?

A Gear Design job involves creating and optimizing gears for mechanical systems, ensuring they meet performance, durability, and efficiency requirements. Engineers in this role use CAD software and engineering principles to design gears for applications in automotive, aerospace, industrial machinery, and more. They analyze factors like load capacity, material selection, and manufacturing processes to ensure reliable gear operation. Collaboration with manufacturing teams and testing prototypes are also key aspects of the job.

What are some of the typical challenges faced in a Gear Design role, and how are they addressed?

Gear Design professionals often deal with challenges such as optimizing gear performance while balancing constraints like weight, cost, and manufacturability. They must account for factors like material selection, load requirements, and noise reduction, all while ensuring the gears can be produced efficiently at scale. Overcoming these challenges usually involves working closely with cross-functional teams—including manufacturing, quality assurance, and R&D—to validate designs and test prototypes. Staying updated with new materials and design methodologies also helps address evolving industry needs. Successful gear designers are adaptable and proactive in researching solutions to deliver innovative and reliable components.

What are popular job titles related to Gear Design jobs in Virginia? For Gear Design jobs in Virginia, the most frequently searched job titles are:
What job categories do people searching Gear Design jobs in Virginia look for? The top searched job categories for Gear Design jobs in Virginia are:
Gear Design jobs near you
Infographic showing various Gear Design job openings in Virginia as of July 2026, with employment types broken down into 56% Full Time, and 44% Part Time. Highlights an 100% In-person job distribution, with an average salary of $83,314 per year, or $40.1 per hour.
Manager - Structural Design

Manager - Structural Design

Reputable Recruiting

Virginia Beach, VA • On-site

$145K - $160K/yr

Full-time

Posted 22 days ago

Job description

Role Overview

Hands-on engineering leader to own the full structural design lifecycle for the company's ultra-class rigid-frame haul trucks (250 to 375 ton machines) built for the world's most demanding mining environments. This is not a caretaker role. The mandate is to elevate a tenured team and set a higher bar for engineering rigor, while personally engaging with the technical challenges that make this work genuinely interesting: fatigue life, weld design, and structural weight optimization.
Responsibilities
  • Lead the Structural Design department (4–6 engineers), including performance reviews, coaching, and personnel decisions
  • Own full structural system design: superstructure, dump body, front/rear running gear, castings, and weld design
  • Drive fatigue life analysis using cyclic load profiles and S-N curves; designing to finite fatigue life, not just static ultimate load
  • Develop and review weld joint designs, including full-penetration welds, fillet vs. groove tradeoffs, and toe geometry
  • Apply 3D modeling using PTC Creo (preferred) or equivalent platform; strong preference for top-down methodology
  • Mentor engineers to understand the physics behind FEA outputs, not just produce results
  • Develop business cases and written justifications to unlock resources and support across the organization
  • Collaborate with cross-functional teams and international counterparts; up to 20% travel
  • Contribute to root cause analysis, failure analysis, and field warranty investigations as needed
Requirements
  • Hands-on structural engineering experience with welded fabrications, castings, and/or heavy machined structures; must have designed or co-designed real hardware
  • Fatigue life analysis depth: cyclic loading, S-N curves, finite fatigue life design
  • Weld design knowledge: full-penetration welds, joint selection, and fatigue impact of geometry decisions
  • Free body diagram fluency; can trace force flow independently from software output
  • Proficiency in 3D modeling (Creo/Pro-E, SolidWorks, CATIA, or Siemens NX)
  • Minimum 2 years directly managing technical staff (reviews, coaching, personnel decisions)
Strong Preferences
  • Heavy equipment structural experience: mining, construction, crane, agriculture, or similar cyclic-loading environment
  • Material selection experience with HSLA steel - weldability, tensile strength, and cold-weather properties
  • Top-down 3D modeling methodology - must be able to discuss and demonstrate approach
  • Sand casting design experience with wall thickness and fatigue geometry considerations
  • Ability to write clear business cases and engineering justifications
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