Metal Forming Simulation Jobs in Virginia (NOW HIRING)

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
As our Senior Manufacturing Engineer - Sheet Metal Fabrication, you'll own the manufacturing engineering function for sheet metal components and assemblies on the EL9 - a clean-sheet Part 23 aircraft. Working within our Integrated Product Development Team (IPDT) and alongside internal and external manufacturing partners, you'll apply Design for Manufacturing (DFM) principles to build efficient, repeatable, cost-effective fabrication processes from the ground up. Machining knowledge will round out your contribution across part finishing and structural integration.
What You'll Do

• Serve as the manufacturing engineering focal point for sheet metal fabrication, including forming, bending, trimming, and assembly of metallic components.
• Collaborate with design and stress engineering teams to incorporate DFM principles into sheet metal part and assembly design.
• Define and implement manufacturing requirements for sheet metal components, including material selection, forming methods, tolerancing, and producibility.
• Develop and optimize sheet metal processes: press forming, stretch forming, brake forming, roll forming, trimming, and deburring.
• Define, specify, and coordinate tooling and fixtures, including dies, forming tools, templates, and check fixtures.
• Interface with Tier 1 and Tier 2 suppliers specializing in sheet metal fabrication to ensure alignment on requirements, schedule, cost, quality, and risk.
• Conduct trade studies and resolve technical challenges related to forming feasibility, springback, distortion, and dimensional control.
• Apply machining process knowledge (CNC trimming, drilling, finishing) to support part completion, tolerance achievement, and assembly integration.
• Establish and document manufacturing standards, work instructions, and best practices for sheet metal fabrication and finishing operations.
• Support make vs. buy decisions and supplier selection strategies for metallic components.
• Contribute to the development of a greenfield fabrication capability, including process flow, factory layout, and equipment selection.

What You Bring

• Bachelor's degree in Mechanical, Manufacturing, or Aerospace Engineering, or a related field.
• 8+ years of experience in aerospace manufacturing or production engineering.
• Strong experience with sheet metal fabrication processes, including forming, bending, and trimming.
• Working knowledge of machining processes such as CNC machining, drilling, and finishing operations.
• Solid understanding of GD&T, tolerancing, and dimensional control for formed and machined parts.
• Excellent cross-functional communication and collaboration skills.
• Proven ability to influence multidisciplinary teams and coordinate with suppliers.
• Equivalent combinations of education and experience will be considered.

Bonus Points

• Experience with aerospace sheet metal structures, including skins, ribs, frames, and brackets.
• Familiarity with forming simulation, springback compensation, and tooling development.
• Background working with aircraft OEMs or Tier 1 suppliers in development and/or production programs.
• Knowledge of special processes such as heat treatment, surface treatments, and chemical milling.
• Experience integrating machined features with formed components in structural assemblies.
• Working knowledge of CAD and PLM tools.

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.

Compensation and Benefits
In addition to offering an exciting work environment and the opportunity to be part of the team making Ultra Short flight a reality, at Electra, we offer an unparalleled total rewards package. Electra offers employees a comprehensive benefits package including medical, dental, vision, STD, LTD, and life insurance, generous PTO and sick leave, company holidays, paid winter break, and a 401(k) plan with immediate vesting. Life at Electra includes a variety of perks, such as free catered lunches, amazing coffee, snacks, drinks, fruit, free parking, and opportunities for much more.
Working Conditions
Work is typically performed in a warehouse/aviation and office environment, which requires proper safety precautions. Work may require some physical effort in handling light materials, boxes, power tools, prototypes, and different materials or equipment. Due to the nature of our business and projects, some fieldwork may be required, working in both indoor and outdoor conditions. You may need to lift up to 50 lbs.
Background & Drug Screening
Successful completion of a background check and/or drug screening prior to starting work may be required for this position.
Commitment
We are committed to fostering diversity and inclusivity, and we encourage individuals from all backgrounds, including those from marginalized or underrepresented groups in the tech industry and aerospace, to apply for our job openings. We firmly believe that a diverse range of perspectives can profoundly influence both our product and our company culture.
Electra is committed to a work environment that is inclusive to all and free of discrimination. It is our policy to be an equal opportunity employer without regard to race, color, religion, sex, age, national origin, disability, sexual orientation, gender identity or expression, genetic predisposition or carrier status, veteran status, citizenship status, or any other factors prohibited by law. Electra will provide reasonable accommodations for qualified individuals.
Electra is an E-Verify employer.