{"id":242562,"url":"https://alion.io/job/electra-seniorprincipal-airframe-stress-engineer","title":"Senior/Principal Airframe Stress Engineer","company":{"id":93694,"name":"Electra","domain":"electra.aero","url":"https://alion.io/company/electra-aero","size_band":"201-500","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Greenhouse","truth_index":null},"role":"Aerospace","role_family":"Aerospace","seniority":"lead","employment_type":null,"work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Manassas, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":130000,"max":180000,"currency":"USD","period":"year","gross":null,"usd_annual":180000},"salary_estimate":null,"experience_years_min":10,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"Femap","optional":false},{"name":"Nastran","optional":false}],"status":"live","first_seen_at":"2026-08-18T13:04:21Z","employer_posted_date":"2026-10-12","last_verified_at":"2026-11-02T21:21:28Z","board_verified":true,"closed_at":null,"days_open":76,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":76},"description":"About Electra\nAir travel is about to become something more: more direct, more accessible, and more connected to the places where people live, work and want to be. Every day in the U.S., people make 35 million trips of 50-500 miles, stuck in traffic or routed through crowded hubs. Chances are, you've been one of them. At Electra, we're changing that with the EL9, a nine-passenger, hybrid-electric aircraft that takes off and lands in just 150 feet. Our Ultra Short technology opens up thousands of new places to fly, beyond conventional runways, congested airports and long drives. We're backed by Lockheed Martin, Honeywell and Safran. Operators worldwide have signed intent-to-purchase agreements for the first 2,200 aircraft we produce, and we're moving toward first test flights in 2027.\nGetting a new kind of aircraft airborne takes more than ambition. It takes our kind of bold: people who think big while working in the real world. Who move ideas into action and collaborate without silos. Who put people first and make room at the table for everyone. Who challenge one another without diminishing one another.\nSound like you? Then look beyond what you thought were your own limits, and help us take flight beyond runways.\nAbout Electra\nAt 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.\nA 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.\nThe Role\nAs 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.\nYou 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.\nWhat You'll Do\nSupport development of major airframe structures from preliminary design through certification, production launch, and manufacturing ramp-up\nPerform static strength, fatigue, and durability analyses for metallic and composite aircraft structures\nDevelop structural substantiation methods and analysis plans supporting FAA Part 23 type certification\nCreate and validate finite element models using FEMAP/Nastran or equivalent analysis tools\nPerform detailed hand calculations using industry-standard methodologies and references including:Bruhn\nNiu\nRoark\nESDU\nClassical mechanics of materials approaches\n\nCollaborate with loads, design, materials & processes, manufacturing, structural test, and certification teams throughout the entire development process\nSupport trade studies and structural design optimization activities\nDefine structural analysis requirements and certification substantiation plans\nReview and approve design dispositions and engineering analyses\nSupport component, subassembly, and full-scale structural testing activities, including:Test planning\nRequirements definition\nInstrumentation support\nData review\nTest reporting\n\nPrepare structural substantiation reports and certification documentation\nPresent structural analyses and recommendations during internal and external design reviews\nSupport supplier technical reviews and provide guidance on structural analysis methodologies\nContribute to the establishment of structural analysis processes, best practices, and design standards\nWhat You'll Bring\nBachelor's degree in Aerospace Engineering, Mechanical Engineering, or related engineering discipline\nExperience in airframe structural analysis supporting aircraft development programs\nStrong knowledge of metallic and composite aircraft structures\nExperience supporting FAA Part 23 and/or Part 25 aircraft certification programs\nAdvanced proficiency with FEMAP/Nastran or equivalent finite element analysis tools\nExperience with NX or similar CAD platforms\nStrong understanding of:Aircraft loads\nFree body diagrams\nStructural load paths\nMechanics of materials\nStructural stability and failure modes\n\nAdvanced proficiency performing both hand calculations and finite element analyses\nExperience developing structural substantiation reports and certification documentation\nStrong technical writing and communication skills\nAbility to work effectively within multidisciplinary engineering teams\nStrong analytical and problem-solving capabilities\nPreferred Qualifications\nMaster's degree in Aerospace Engineering, Mechanical Engineering, or related discipline\nExperience supporting aircraft programs from conceptual design through certification and production\nExperience with composite airframe design and certification\nExperience supporting structural testing and correlation of analytical models\nFamiliarity with hybrid-electric, eSTOL, eVTOL, or advanced air mobility aircraft programs\nExperience working directly with regulatory authorities during certification efforts\nExperience mentoring engineers and reviewing structural analyses\nU.S. Person (U.S. Citizen or Green Card holder) preferred\nLocation & Travel\nLocation: Manassas, VA Headquarters. This position requires regular onsite presence to support collaboration with engineering, manufacturing, and test teams.\nTravel: Minimal\nLeveling Expectations\nLevel (Senior or Principal) will be determined based on the candidate's experience, technical expertise, demonstrated leadership, and ability to influence aircraft development decisions.\nBoth 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.\nSenior Airframe Stress Engineer (8+ Years)\nDemonstrates strong expertise in aircraft structural analysis and airframe certification\nIndependently performs static, fatigue, and damage tolerance analyses\nDevelops structural substantiation packages for FAA certification activities\nCreates and validates finite element models and analytical methodologies\nCollaborates effectively across design, loads, certification, and test organizations\nSupports structural testing, correlation activities, and certification efforts\nProvides technical guidance within assigned programs and workstreams\nDrives resolution of complex structural engineering challenges with minimal supervision\nPrincipal Airframe Stress Engineer (10+ Years)\nRecognized subject matter expert in aircraft structural analysis and certification\nLeads major structural development efforts across large airframe assemblies and programs\nEstablishes structural analysis methodologies, standards, and best practices\nServes as a key technical authority for certification substantiation strategies\nDrives structural architecture decisions balancing weight, manufacturability, performance, and certification requirements\nLeads critical technical reviews and influences program-level engineering decisions\nMentors engineers across the organization and elevates overall technical capability\nActs as a primary interface with certification authorities, suppliers, and external partners on structural matters\nProvides strategic technical leadership throughout aircraft development, certification, and production readiness efforts\nThis 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.\nCompensation Range\n$130,000—$180,000 USD\nWhat We Offer\nMedical, dental, and vision insurance; STD, LTD, and life insurance\nGenerous PTO, sick leave, and company holidays\nPaid winter break\n401(k) with immediate vesting\nFree catered lunches, coffee, snacks, and drinks at our Manassas headquarters\nFree on-site parking\nElectra is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, national origin, disability, veteran status, or any other characteristic protected by law. 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