Mechanical Product Development Engineer, Prototyping to Production

Role snapshot

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.

Core responsibilities

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.

Technical scope & constraints

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.

Required qualifications 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.

Preferred experience

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, gaskets, fasteners.

Prototype-to-production transitions; managing small engineering projects from concept to release.

Clear technical communication across engineers, operators, customers, suppliers, and leadership; passion for American industry and defense technology.

Capabilities that set you apart

Mechanical architecture for complex systems3D…