Manufacturing Design Engineer Jobs in Washington

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.

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.

• 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.

• 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).

• 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.

• 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: Manassas, VA headquarters (on-site presence strongly preferred).

• Travel: Occasional (<10%).