End-to-End Mechanical Engineer, Defense Hardware

Kform; Sterling (VA); On-site; USD 85,000 - 120,000; Full time

Job summary

Kform is seeking a qualified Mechanical Design Engineer in Sterling, VA, to own mechanical product development from concept to production readiness. You will work at the intersection of design, test, manufacturing, and quality to deliver robust systems and iterate rapidly with shop tools and test equipment.

Ideal candidates have 3–5 years in mechanical design, strong CAD fundamentals, SolidWorks expertise, and hands-on experience with rapid prototyping and electronics packaging.

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 SolidWorks (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.

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.

Skills

CAD modeling

SolidWorks

DFM

GD&T

Fabrication methods

Electronics packaging

Cable routing

Problem solving

Documentation

Cross-functional teamwork

Education

BS in Mechanical Engineering

Related field

Tools

Onshape

Inspection tools

Job description

Kform is seeking a qualified Mechanical Design Engineer in Sterling, VA, to own mechanical product development from concept to production readiness. You will work at the intersection of design, test, manufacturing, and quality to deliver robust systems and iterate rapidly with shop tools and test equipment.

Ideal candidates have 3–5 years in mechanical design, strong CAD fundamentals, SolidWorks expertise, and hands-on experience with rapid prototyping and electronics packaging.