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Senior Process Engineer Jobs in Virginia (NOW HIRING)

Heico

Process Engineer

Blacksburg, VA · On-site

$65K - $125K/yr

Reporting to the Process Engineering Manager, the Process Engineer will be a key member within our Quality Department. Responsibilities will include: * Support our overseas manufacturing site by ...

HEICO

Process Engineer

Blacksburg, VA · On-site

$65K - $125K/yr

Reporting to the Process Engineering Manager, the Process Engineer will be a key member within our Quality Department. Responsibilities will include: * Support our overseas manufacturing site by ...

HEICO

Process Engineer

Blacksburg, VA · On-site

$65K - $125K/yr

Reporting to the Process Engineering Manager, the Process Engineer will be a key member within our Quality Department. Responsibilities will include: * Support our overseas manufacturing site by ...

Black & Veatch

Sr. PFAS Process Engineer

Virginia Beach, VA · Hybrid

$91K - $118K/yr

Why BVs Process Engineering Team? * The work is rewarding and meaningful * The team is comprised of supportive and appreciative professionals * Career opportunities exist in many rapidly expanding ...

Black & Veatch

Sr. PFAS Process Engineer

Arlington, VA · On-site

$119K - $154K/yr

The Black & Veatch Process Engineers develop technical solutions that are critical to winning work and drive design deliverables for critical infrastructure projects with community benefits. Our Team ...

Black & Veatch

Sr. PFAS Process Engineer

Arlington, VA · Hybrid

$119K - $155K/yr

The Black & Veatch Process Engineers develop technical solutions that are critical to winning work and drive design deliverables for critical infrastructure projects with community benefits. Our Team ...

Black & Veatch

Sr. PFAS Process Engineer

Richmond, VA · Hybrid

$101K - $131K/yr

The Black & Veatch Process Engineers develop technical solutions that are critical to winning work and drive design deliverables for critical infrastructure projects with community benefits. Our Team ...

Kelly Services

Process Engineer

New Market, VA · On-site

$100K/yr

Process Engineer Location: New Market, VA Employment Type: Full-Time | Direct Hire Salary Range: Up to $100,000+ (DOE) annually Position Summary The Process Engineer is responsible for supporting and ...

Black & Veatch

Sr. PFAS Process Engineer

Arlington, VA · Hybrid

$119K - $155K/yr

Why BVs Process Engineering Team? * The work is rewarding and meaningful * The team is comprised of supportive and appreciative professionals * Career opportunities exist in many rapidly expanding ...

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All JobsProcess Engineer JobsSenior Process Engineer JobsSenior Process Engineer Jobs in Virginia

Senior Process Engineer information

See Virginia salary details

$74.4K

$120.1K

$169K

How much do senior process engineer jobs pay per year?

As of Jul 14, 2026, the average yearly pay for senior process engineer in Virginia is $120,077.00, according to ZipRecruiter salary data. Most workers in this role earn between $103,100.00 and $133,300.00 per year, depending on experience, location, and employer.

What is the difference between Senior Process Engineer vs Process Engineer?

AspectSenior Process EngineerProcess Engineer
QualificationsBachelor's or Master's in Engineering, often with 5+ years experienceBachelor's degree in Engineering or related field, typically 1-3 years experience
ResponsibilitiesLeading process improvements, mentoring, project managementSupporting process development, data analysis, assisting senior staff
Work EnvironmentDesign teams, manufacturing plants, R&D departmentsManufacturing facilities, engineering teams, operational support

Senior Process Engineers typically have more experience, leadership duties, and oversee complex projects, while Process Engineers focus on supporting process development and implementation. Both roles are essential in manufacturing and engineering industries, but the senior role involves greater responsibility and strategic planning.

What are the key skills and qualifications needed to thrive as a Senior Process Engineer, and why are they important?

To thrive as a Senior Process Engineer, you need a strong background in chemical or process engineering, problem-solving skills, and typically a bachelor's or master's degree in a relevant field. Expertise in process simulation software (such as Aspen Plus or HYSYS), Six Sigma or Lean certifications, and familiarity with process control systems are highly valued. Outstanding analytical abilities, leadership, and effective communication set top performers apart in this role. These skills and qualifications are crucial for optimizing processes, ensuring safety and compliance, and leading teams to achieve operational excellence.

What does a Senior Process Engineer do?

A Senior Process Engineer is responsible for designing, optimizing, and overseeing processes within manufacturing or production environments. They analyze workflows, troubleshoot issues, and implement improvements to increase efficiency, safety, and product quality. Senior Process Engineers often lead projects, mentor junior engineers, and collaborate with cross-functional teams to ensure operational excellence. Their expertise is vital in industries like chemicals, pharmaceuticals, oil and gas, and food processing.

What are some common challenges Senior Process Engineers face when working on cross-functional teams?

Senior Process Engineers often collaborate with professionals from various departments, such as operations, quality, and maintenance. A common challenge is aligning diverse priorities and communication styles to achieve shared project goals. Successfully managing these differences requires strong interpersonal and project management skills, as well as the ability to translate technical concepts for non-engineering colleagues. Regular meetings and clear documentation can help ensure everyone stays informed and engaged throughout the process.
What are the most commonly searched types of Process Engineer jobs in Virginia? The most popular types of Process Engineer jobs in Virginia are:
What are popular job titles related to Senior Process Engineer jobs in Virginia? For Senior Process Engineer jobs in Virginia, the most frequently searched job titles are:
What job categories do people searching Senior Process Engineer jobs in Virginia look for? The top searched job categories for Senior Process Engineer jobs in Virginia are:
What cities in Virginia are hiring for Senior Process Engineer jobs? Cities in Virginia with the most Senior Process Engineer job openings:
What are popular job titles related to Senior Process Engineer jobs in VA? For Senior Process Engineer jobs in VA, the most frequently searched job titles are:
Senior Process Engineer jobs near you
Infographic showing various Senior Process Engineer job openings in Virginia as of July 2026, with employment types broken down into 3% Locum Tenens, 91% Full Time, 3% Part Time, and 3% Contract. Highlights an 87% Physical, 4% Hybrid, and 9% Remote job distribution, with an average salary of $120,077 per year, or $57.7 per hour.
Senior Materials, Process, & Test Engineer

Senior Materials, Process, & Test Engineer

Electra

Manassas, VA • On-site

$130K - $160K/yr

Full-time

Medical, Dental, Vision, Life, Retirement, PTO

Re-posted 2 days ago

Job description

Senior Materials, Process, & Test Engineer
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 matter at this stage - and this role is no exception.
The Role
Electra.aero, a next-gen aerospace technology company, seeks a dynamic and driven Senior Materials, Process, & Test Engineer. This role will lead the development, selection, testing, and certification of advanced materials and processes for Electra's 9-passenger hybrid-electric eSTOL (electric short takeoff and landing) aircraft. The ideal candidate will have a strong background in aerospace materials and processes, structural and environmental testing, and certification pathways. This role requires a hands-on engineer who thrives in a collaborative, fast-paced environment and is excited to shape the materials and processes that enable next-generation aviation.
What You'll Do
  • Developing and qualifying new materials, processes, and joining technologies for composite and metallic airframe structures.
  • Leading material and process specifications, including supplier coordination and approval.
  • Designing and executing test campaigns (coupon-level through full-scale) to validate performance, safety, and compliance.
  • Applying knowledge of FAA Part 23 requirements, ASTM standards, and industry best practices for materials and process qualification.
  • Driving structural and material trade studies to balance weight, manufacturability, durability, and cost.
  • Supporting failure investigations, root-cause analysis, and corrective actions related to material performance.
  • Interfacing with suppliers and manufacturing teams to ensure successful process implementation and scale-up.
  • Preparing and presenting at internal and external design/test reviews to demonstrate compliance and readiness.
  • Communicating technical information effectively across engineering teams, leadership, suppliers, and regulatory bodies.

What You Bring
  • Bachelor's degree in Materials Science, Mechanical, or Aerospace Engineering (or related STEM discipline).
  • Minimum 5+ years of experience in aerospace materials and processes, including composite and metallic structures.
  • Expertise in aerospace material systems (metallic alloys, composites, adhesives, coatings, etc.).
  • Strong understanding of material processing methods (lamination, curing, heat treatment, bonding, welding, additive manufacturing, etc.).
  • Experience in design, planning, and execution of structural and environmental test programs.
  • Knowledge of certification pathways for materials and processes under FAA Part 23 or Part 25.
  • High competence with engineering fundamentals and ability to translate test data into actionable design/process insights.
  • Excellent organizational, analytical, and communication skills.
  • Strong work ethic and ability to independently lead projects from concept through validation.

Bonus Points
  • Excellent communication, interpersonal, and leadership skills.

Compensation:
$130,000.00 - $160,000.00 annually. 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.
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.

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