Mechanical Design Engineer

X-PRO LLC is seeking an experienced Mechanical Engineer located in Virginia, preferably within commuting distance of Fairfax
, to support ongoing engineering, manufacturing, and product-development projects.

The ideal candidate will have strong practical experience with CNC machining, manufacturing processes, mechanical assemblies,injection molding, and production-ready CAD design
. We are looking for someone who understands not only how to design a component, but also how that component will actually be manufactured, assembled, inspected, and improved.

• Develop and modify 3D CAD models, mechanical parts, and assemblies
• Create manufacturing-ready 2D engineering drawings
• Design components specifically for CNC machining and other manufacturing processes
• Review designs for DFM/DFA (Design for Manufacturing and Assembly)
• Develop mechanical assemblies, interfaces, mounting systems, brackets, enclosures, fixtures, and related components
• Select appropriate materials, tolerances, fits, fasteners, and manufacturing methods
• Review vendor and machine-shop feedback and implement necessary design changes
• Troubleshoot mechanical and manufacturing issues
• Support prototype fabrication, assembly, inspection, testing, and design validation
• Work directly with CNC shops, fabricators, suppliers, and other manufacturing partners when required
• Reverse-engineer existing components and assemblies when necessary
• Develop innovative solutions when standard approaches are not practical
• Support projects from initial concept through prototype and production release

• Degree in Mechanical Engineering or a closely related engineering field
• Strong proficiency with professional 3D CAD software
• Hands-on understanding of CNC milling and turning
• Good understanding of machining limitations, tooling access, setups, tolerances, and achievable surface finishes
• Experience creating detailed manufacturing drawings using GD&T and standard engineering practices
• Experience designing multi-part mechanical assemblies
• Knowledge of common engineering materials including aluminum, stainless steel, carbon steel, plastics, and engineering polymers
• Ability to independently analyze a problem and develop practical engineering solutions
• Strong attention to detail and ability to work on technically demanding projects
• Ability to communicate effectively with machinists, manufacturers, vendors, and engineering team members
• Must be based in Virginia and able to travel to the Fairfax, VA area when required

• CNC machining or machine-shop environments
• Prototype development
• Reverse engineering
• Production tooling and fixtures
• Sheet metal fabrication
• Welding and fabricated assemblies
• Injection molding
• Mechanical testing and validation
• Product development
• Defense, aerospace, industrial, or government-related engineering projects
• BOM development and engineering documentation
• Design optimization for low-volume and production manufacturing

This position is best suited for an engineer who is creative, practical, and manufacturing-focused
. We value engineers who can look at a mechanical problem, understand the real-world manufacturing constraints, and develop a solution rather than simply producing a CAD model.

You should be comfortable working independently, taking ownership of engineering tasks, and collaborating with both engineering and manufacturing personnel.

This is a hybrid position
. Much of the CAD, documentation, and engineering work can be completed remotely, while certain projects will require on-site work in the Fairfax / Northern Virginia area for activities such as:

• Reviewing physical components
• Taking measurements
• Reverse engineering
• Prototype assembly
• Testing and troubleshooting
• Manufacturing coordination
  
  Design reviews

The exact schedule can be flexible depending on project requirements.