Mechanical Product Development Engineer, Prototyping to Production
Job in
Sterling, Loudoun County, Virginia, 22170, USA
Listed on 2026-09-21
Listing for:
Kform
Full Time
position Listed on 2026-09-21
Job specializations:
-
Engineering
Mechanical Engineer, Manufacturing Engineer, Product Engineer, Quality Engineering
Job Description & How to Apply Below
- Own mechanical product development for defense and dual-use hardware—from concept to production readiness.
- Operate at the intersection of design, test, manufacturing, and quality to deliver robust, buildable systems quickly.
- Stay close to the work: CAD in the morning, test bench at noon, machine shop in the afternoon, supplier call before close.
- Own mechanical product development for defense and dual-use hardware—from concept to production readiness.
- Operate at the intersection of design, test, manufacturing, and quality to deliver robust, buildable systems quickly.
- Stay close to the work: CAD in the morning, test bench at noon, machine shop in the afternoon, supplier call before close.
- Architect and design: assemblies; ruggedized enclosures; brackets, mounts, panels, and structural components; mechanisms and interfaces; thermal solutions; fixtures/tooling; test equipment; production-ready components.
- Produce complete design packages: models, drawings, assemblies, BOMs, revision history, assembly instructions, and design rationale/trade studies.
- Prototype rapidly and iterate using shop tools, inspection equipment, and test instrumentation.
- Close the loop with manufacturing, quality, supply chain, and program teams to hit targets on manufacturability, assembly, inspection, cost, schedule, and reliability.
- Plan and run validation for fit/function, structural and durability performance, thermal response, manufacturability, assembly workflows, safety, and reliability.
- Analyze failures and test data; execute evidence-based design improvements.
- Collaborate directly with machinists, fabricators, vendors, and production to ensure design intent is realized.
- Mentor junior engineers; independently manage small projects from ambiguous requirements to delivered outcomes.
- Continuously improve Kform’s engineering and manufacturing processes.
- Constraints you’ll balance: packaging, weight, thermal performance, environmental exposure, shock/vibration, EMI/shielding, assembly sequence, serviceability, cost, and lead time.
- Interfaces you’ll manage: mechanical to electrical, embedded integration, cable routing, and test/inspection touchpoints.
- BS in Mechanical, Mechatronics, Aerospace, Manufacturing Engineering, or related field.
- 3–5 years in mechanical design, product development, prototyping, test, manufacturing engineering, or multidisciplinary hardware development.
- Strong fundamentals: CAD modeling; assemblies; materials; tolerancing; fabrication methods; structural design; DFM.
- Advanced proficiency in Solid Works (or equivalent) and production-quality drawings with dimensions, tolerances/GD&T, notes, finishes, and revision control.
- Hands-on proficiency with rapid prototyping, shop equipment, inspection tools, test equipment, and hardware bring-up.
- Working knowledge of electronics packaging, cable routing, thermal management, embedded systems integration, manufacturing, quality, test, and systems integration.
- Clear documentation habits and strong problem-solving; effective independently and on cross-functional teams.
- Startup or high-accountability roles.
- Defense, aerospace, robotics, industrial automation, advanced manufacturing, rugged electronics, or other regulated environments.
- Ruggedization for field use: enclosures, cases, packaging for electronics, production fixtures.
- AS9100, QMS, configuration control, production documentation, and design release processes.
- Environmental, shock, vibration, thermal, ingress protection, and EMI design considerations.
- Design for manufacturability, assembly, inspection, reliability, and cost; supplier collaboration across CNC, sheet metal, additive, composites, castings, coatings,…
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