Metallurgy Process Engineer Jobs in Virginia (NOW HIRING)

At Electra, we're building hybrid-electric Ultra Short Takeoff and Landing aircraft that redefine regional air travel. Our technology enables aircraft to take off and land in soccer field-sized spaces, unlocking thousands of new operating locations and enabling what we call Direct Aviation: quiet, efficient, point-to-point travel closer to where people live and work.

A global company headquartered in Manassas, VA, with additional operations in Switzerland, Electra is backed by industry leaders and is advancing toward certification. We're a growing team of innovators working at the forefront of sustainable aviation-every hire plays a critical role in shaping the future of flight.

As a Senior or Principal Airframe Stress Engineer, you will lead structural analysis efforts supporting the development, certification, and production of Electra's flagship hybrid-electric eSTOL aircraft. This role is responsible for ensuring the structural integrity of metallic and composite airframe components through detailed analysis, testing, and certification substantiation.

You will work closely with design engineering, loads, materials & processes, manufacturing, structural test, suppliers, and certification teams to develop robust airframe structures that meet performance, safety, and FAA certification requirements. The ideal candidate combines deep structural analysis expertise with strong engineering judgment and the ability to influence aircraft design decisions throughout the product lifecycle.

• Support development of major airframe structures from preliminary design through certification, production launch, and manufacturing ramp-up
• Perform static strength, fatigue, and durability analyses for metallic and composite aircraft structures
• Develop structural substantiation methods and analysis plans supporting FAA Part 23 type certification
• Create and validate finite element models using FEMAP/Nastran or equivalent analysis tools
• Perform detailed hand calculations using industry-standard methodologies and references including:
  • Bruhn
  • Niu
  • Roark
  • ESDU
  • Classical mechanics of materials approaches
• Collaborate with loads, design, materials & processes, manufacturing, structural test, and certification teams throughout the entire development process
• Support trade studies and structural design optimization activities
• Define structural analysis requirements and certification substantiation plans
• Review and approve design dispositions and engineering analyses
• Support component, subassembly, and full-scale structural testing activities, including:
  • Test planning
  • Requirements definition
  • Instrumentation support
  • Data review
  • Test reporting
• Prepare structural substantiation reports and certification documentation
• Present structural analyses and recommendations during internal and external design reviews
• Support supplier technical reviews and provide guidance on structural analysis methodologies
• Contribute to the establishment of structural analysis processes, best practices, and design standards

• Bachelor's degree in Aerospace Engineering, Mechanical Engineering, or related engineering discipline
• Experience in airframe structural analysis supporting aircraft development programs
• Strong knowledge of metallic and composite aircraft structures
• Experience supporting FAA Part 23 and/or Part 25 aircraft certification programs
• Advanced proficiency with FEMAP/Nastran or equivalent finite element analysis tools
• Experience with NX or similar CAD platforms
• Strong understanding of:
  • Aircraft loads
  • Free body diagrams
  • Structural load paths
  • Mechanics of materials
  • Structural stability and failure modes
• Advanced proficiency performing both hand calculations and finite element analyses
• Experience developing structural substantiation reports and certification documentation
• Strong technical writing and communication skills
• Ability to work effectively within multidisciplinary engineering teams
• Strong analytical and problem-solving capabilities

• Master's degree in Aerospace Engineering, Mechanical Engineering, or related discipline
• Experience supporting aircraft programs from conceptual design through certification and production
• Experience with composite airframe design and certification
• Experience supporting structural testing and correlation of analytical models
• Familiarity with hybrid-electric, eSTOL, eVTOL, or advanced air mobility aircraft programs
• Experience working directly with regulatory authorities during certification efforts
• Experience mentoring engineers and reviewing structural analyses
• U.S. Person (U.S. Citizen or Green Card holder) preferred

Location: Manassas, VA Headquarters. This position requires regular onsite presence to support collaboration with engineering, manufacturing, and test teams.

Travel: Minimal

Level (Senior or Principal) will be determined based on the candidate's experience, technical expertise, demonstrated leadership, and ability to influence aircraft development decisions.

Both levels require expertise in aircraft structural analysis, certification substantiation, and aircraft development. Differentiation is based on technical leadership, scope of responsibility, independence, and organizational influence.

• Demonstrates strong expertise in aircraft structural analysis and airframe certification
• Independently performs static, fatigue, and damage tolerance analyses
• Develops structural substantiation packages for FAA certification activities
• Creates and validates finite element models and analytical methodologies
• Collaborates effectively across design, loads, certification, and test organizations
• Supports structural testing, correlation activities, and certification efforts
• Provides technical guidance within assigned programs and workstreams
• Drives resolution of complex structural engineering challenges with minimal supervision

• Recognized subject matter expert in aircraft structural analysis and certification
• Leads major structural development efforts across large airframe assemblies and programs
• Establishes structural analysis methodologies, standards, and best practices
• Serves as a key technical authority for certification substantiation strategies
• Drives structural architecture decisions balancing weight, manufacturability, performance, and certification requirements
• Leads critical technical reviews and influences program-level engineering decisions
• Mentors engineers across the organization and elevates overall technical capability
• Acts as a primary interface with certification authorities, suppliers, and external partners on structural matters
• Provides strategic technical leadership throughout aircraft development, certification, and production readiness efforts

$130,000.00 – $180,000.00 annually. This range reflects the anticipated hiring range across all eligible locations; actual compensation is determined based on relevant experience, education, skills, level, and geographic location. Total compensation includes performance bonus, equity eligibility, and comprehensive benefits.

• 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
• Opportunity to help design, certify, and bring to market a groundbreaking hybrid-electric aircraft that will redefine regional air mobility through Direct Aviation.