Mechanical Engineer

100Hires, Inc.; Sterling (VA); On-site; USD 90,000 - 120,000; Full time

Job summary

Kform is a next-generation defense manufacturer seeking a hands-on Mechanical Engineer to lead design, prototyping, testing, and production readiness of complex hardware for defense and dual-use customers.

You will work across mechanical, electrical, software, manufacturing, and quality domains, translating requirements into practical designs and driving hardware from idea to fielded production with an emphasis on manufacturability and reliability.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Mechatronics, Aerospace Engineering, Manufacturing Engineering, or a related technical field.
• 3–5 years of experience in mechanical design and hardware development.
• Experience with design for manufacturability and production readiness.

Responsibilities

• Lead the mechanical design and development of complex hardware products, including: mechanical assemblies, enclosures & ruggedized systems, brackets, mounts, panels, and structural components, as well as thermal management features, mechanisms, fixtures and tooling, and test equipment.
• Create production-quality CAD models, drawings, assemblies, and documentation in SolidWorks.
• Translate customer requirements and field conditions into practical mechanical designs.
• Collaborate across disciplines to understand how mechanical, electrical, software, and manufacturing decisions affect the final product.
• Rapidly prototype proof-of-concept designs using hands-on iteration and fabrication tools.
• Build, assemble, inspect, and troubleshoot prototypes and production-intent hardware.
• Plan and execute testing to validate fit, function, structural durability, thermal behavior, manufacturability, assembly, safety, and reliability.
• Analyze test results, identify failure modes, and drive design improvements with evidence.
• Maintain engineering documentation: CAD models, drawings, BOMs, revision history, assembly instructions, test results, design rationale, and trade studies.

Skills

CAD modeling

Mechanical design

Tolerance analysis

GD&T awareness

Documentation

Problem solving

Education

Bachelor's degree in Mechanical Engineering or related field

Tools

SolidWorks

Onshape

3D modeling

Job description

Kform is a next-generation defense manufacturer helping leading defense and dual-use startups turn advanced technology into producible hardware. We work across design, engineering, prototyping, manufacturing, quality, and production readiness to move critical products from concept to fielded reality.We are recruiting mechanical engineers who want to build real systems, solve hard physical problems, and move fast enough to meet the timelines defense technology demands. The battlefield waits weeks, not years.The right person for this role has strong mechanical engineering depth and enough curiosity, range, and practical ability to work across the rest of the product development stack. You may be strongest in mechanical design, product architecture, thermal management, ruggedization, enclosures, fixtures, mechanisms, or manufacturing, but you want to understand how the whole machine works.At Kform, you will not be trapped in a narrow lane. You will design, prototype, test, troubleshoot, document, and improve real hardware. You will work with engineers, technicians, machinists, suppliers, quality teams, customers, and production teams. You will learn the full scope of product development because you will be close to the work from idea to prototype to production.This is one of the few places where mechanical engineers get to build things that matter, learn fast, and help strengthen American industrial capacity for defense.The RoleYou will lead the mechanical design, prototyping, testing, and production readiness of complex hardware products for defense and dual-use customers. You will bring strong technical depth in mechanical engineering while working across electrical, embedded software, manufacturing, quality, and test domains.This is a hands-on engineering role. You should be comfortable moving between:CADPrototypesMachine shopsTest benchesInspection toolsSupplier conversationsProduction feedbackCustomer requirementsWe want people who read trade magazines, watch factory walkthroughs on YouTube, take things apart, study how products are made, and learn difficult skills because they cannot help themselves.What You Will DoLead the mechanical design and development of complex hardware products, including:Mechanical assembliesEnclosures and ruggedized systemsBrackets, mounts, panels, and structural componentsThermal management featuresMechanisms and interfacesFixtures and toolingTest equipmentProduction-ready componentsCreate detailed mechanical designs, drawings, assemblies, and technical documentation in SolidWorks.Translate customer requirements, system constraints, and field-use conditions into practical mechanical designs.Work across disciplines to understand how mechanical, electrical, software, manufacturing, and quality decisions affect the final product.Design around real-world constraints, including:PackagingWeightThermal performanceEnvironmental exposureShock and vibrationEMI and shielding considerationsAssembly sequenceServiceabilityCost and lead timeRapidly prototype proof-of-concept designs using practical engineering judgment, fabrication tools, test equipment, and hands-on iteration.Build, assemble, inspect, and troubleshoot prototypes and production-intent hardware.Plan and execute testing to validate:Fit and functionStructural performanceDurabilityThermal behaviorManufacturabilityAssembly processSafety and reliabilityAnalyze test results, identify failure modes, and drive design improvements based on evidence.Create and maintain engineering documentation, including:CAD modelsDrawingsBOMsRevision historyAssembly instructionsTest resultsDesign rationaleTechnical trade studiesCollaborate with manufacturing, quality, supply chain, and program teams to improve designs for:ManufacturabilityAssemblyInspectionCostScheduleReliabilityWork directly with machinists, fabricators, vendors, and production teams to close the loop between design intent and physical output.Mentor junior engineers by modeling technical rigor, practical problem-solving, strong documentation, and extreme ownership.Manage smaller engineering projects independently, driving them from ambiguous requirements to completed outcomes.Contribute to continuous improvement across Kform’s engineering and manufacturing systems.What We Are Looking ForWe are looking for a mechanical engineer with real technical depth and broad technical curiosity.You should have strong mechanical engineering fundamentals and enough working knowledge of adjacent disciplines to build complete products with a multidisciplinary team.You do not need to be an expert in everything. You do need to be the kind of person who wants to understand the whole system.You should be comfortable in ambiguity, willing to make technical tradeoffs, and capable of turning incomplete information into forward progress. You should be able to:Sit at a CAD workstation and develop a designBuild or modify a prototypeInspect a machined or fabricated partUnderstand how electrical and mechanical interfaces affect each otherWalk the production floor and gather useful feedbackRun a testDiagnose a failureExplain your reasoning clearlyThe best fit for this role is curious, practical, disciplined, and biased toward action.Minimum QualificationsBachelor’s degree in Mechanical Engineering, Mechatronics, Aerospace Engineering, Manufacturing Engineering, or a related technical field.3 to 5 years of experience in mechanical design, product development, prototyping, test, manufacturing engineering, or multidisciplinary hardware development.Strong technical capability in mechanical engineering fundamentals, including:CAD modelingMechanical assembliesMaterialsTolerancingFabrication methodsStructural designDesign for manufacturabilityAdvanced proficiency in SolidWorks or a comparable mechanical CAD tool.Ability to create production-quality drawings with clear dimensions, tolerances, notes, materials, finishes, and revision control.Hands-on experience with rapid prototyping, fabrication tools, shop equipment, inspection tools, test equipment, and physical hardware.Working knowledge of adjacent disciplines such as:Electronics packagingCable routingThermal managementEmbedded systems integrationManufacturingQualityTestSystems integrationAbility to document engineering work clearly, including design intent, revisions, test results, and technical decisions.Strong problem-solving skills and the ability to work independently while contributing effectively to a multidisciplinary team.Preferred QualificationsFounding, early-employee, or high-accountability startup experience.Experience in defense, aerospace, robotics, industrial automation, advanced manufacturing, rugged electronics, or another regulated technical environment.Experience designing ruggedized systems, tactical hardware, field equipment, enclosures, transport cases, electronics packaging, or production fixtures.Familiarity with AS9100, quality management systems, configuration control, production documentation, and design release processes.Experience with environmental, shock, vibration, thermal, ingress protection, or EMI-related design considerations.Experience designing for manufacturability, assembly, inspection, reliability, and cost.Experience working directly with CNC machining, sheet metal, additive manufacturing, composites, castings, coatings, gaskets, fasteners, and production suppliers.Experience taking hardware from prototype through production readiness.Experience managing small engineering projects from concept through prototype or production release.Demonstrated interest in manufacturing, American industry, defense technology, and hard technical problems.Strong communication skills with the ability to explain technical decisions to engineers, operators, customers, suppliers, and leadership.Skills That Matter HereMechanical design and 3D modeling in SolidWorks.Mechanical architecture for complex hardware systems.Design for manufacturability, assembly, inspection, and production readiness.Tolerance analysis, GD&T awareness, and practical drawing discipline.Materials, finishes, fasteners, joining methods, and fabrication process selection.Electronics packaging, cable routing, thermal management, and mechanical integration.Prototype fabrication, assembly, instrumentation, inspection, and test.Fixture, tooling, and test equipment design.Technical documentation and configuration discipline.Analytical thinking, practical judgment, and attention to detail.Ability to operate with urgency while maintaining engineering rigor.Ownership mindset, strong follow-through, and commitment to building products that matter.Working EnvironmentThis role operates in a fast-moving product development and manufacturing environment.You should expect:Frequent hands-on work with prototypes, tools, machinery, test equipment, inspection equipment, electronics, and production hardware.Time spent standing, walking, assembling, testing, troubleshooting, inspecting parts, or working near active manufacturing and prototyping operations.Use of personal protective equipment depending on the task, equipment, and work area.Occasional travel to support customers, suppliers, testing, or program needs.How We WorkKform values continuous improvement, aggressive value creation, and extreme ownership.We are building the infrastructure, technical capability, and execution engine required to bring advanced defense products into production faster. That requires people who care about the details, respect the customer, understand physical hardware, and know that American industrial strength is built by people who can execute.If you want to learn the full scope of product development, build real hardware, work with exceptional startups, and help create defense products that matter, this is the work.You should be proficient in:CAD SoftwareMechanical Design & EngineeringMachines & technologies you'll use:3D Modeling (Solidworks)CAD Software (Solidworks, Onshape)