Mechanical Engineer

CoAspire; Washington (District of Columbia); On-site; USD 80,000 - 100,000; Full time

Benefits offered by this job

Medical, dental and vision benefits from day one

401(k) with generous company match

PTO and Federal holidays

Job summary

CoAspire in Washington, DC is seeking a Manufacturing/Process Engineer to lead assembly optimization and ensure compliance with quality standards. The role involves hands-on collaboration with cross-functional teams and focuses on innovative solutions for high-rate production.

The ideal candidate will have a Bachelor's degree in Mechanical Engineering, with 2-8 years of relevant experience and expertise in GD&T. Comprehensive benefits, including medical and 401(k), are offered from day one.

Qualifications

• 2-8 years of hands-on manufacturing/process engineering experience in aerospace/defense production.
• Proven track record of cost reduction and assembly time improvement programs.
• Knowledge of aerospace materials, fasteners, and manufacturing processes.

Responsibilities

• Drive assembly process optimization for weapon systems.
• Participate in Design-for-Manufacturing reviews.
• Identify and qualify lower-cost alternative parts.

Skills

Cost reduction

Assembly process optimization

GD&T expertise

Mechanical drawing interpretation

Excellent communication

Education

Bachelor’s degree in Mechanical Engineering or related field

Tools

PLM/ERP systems (e.g., WindChill)

Job description

CoAspire is a cutting-edge defense manufacturing leader in Northern Virginia, specializing in the precision assembly of advanced weapons systems. With over twelve years of a legacy of innovation, we're at the forefront of building reliable, affordable mass weapons that protect and empower our nation’s warfighters. Our tight-knit team thrives in a collaborative environment where safety, quality, and work‑life balance come first with a focus on professional growth at our new 27,000+ sq. ft. facility. Join us to make a tangible impact on mission‑critical technology while enjoying Northern Virginia's vibrant community.

What you will do

You will work out of either our Headquarters in Fairfax, VA or our production facility in Manassas, VA to drive assembly process optimization, cost reduction, and design‑for‑manufacturability improvements for weapon systems. You will identify and implement changes to mechanical parts, connectors, fasteners, harnesses, brackets, and subsystems to dramatically reduce build time, lower material costs, eliminate production bottlenecks, and support affordable high‑rate manufacturing — all while maintaining full compliance with government performance, quality, and safety standards. This hands‑on role works side‑by‑side with a senior mechanical engineering lead, technicians, quality, procurement, and design engineering to transition products from prototype/design models to sustained high‑volume production.

Responsibilities

• Participate and contribute to Design‑for‑Manufacturing/Assembly (DFM/DFA) reviews and value engineering initiatives to simplify mechanical designs, standardize components, and reduce part count/SKU proliferation.
• Identify and qualify lower‑cost alternative parts, connectors, cables, fasteners, and materials (COTS/MIL SPEC) that meet form/fit/function, environmental, and ITAR requirements while achieving reduced cost savings.
• Optimize assembly sequences, tooling, fixtures, and work instructions to cut assembly time, reduce labor hours, and improve first‑pass yield on the production line.
• Perform root‑cause analysis on production issues (fit issues, non‑conformances, rework) and implement corrective actions, including ECNs and drawing updates.
• Collaborate with supply chain and suppliers on make‑vs‑buy decisions, vendor qualifications, and long‑term agreements to secure cost‑effective, reliable sources.
• Support and contribute to manufacturing bills of materials (MBOMs), routings, and process flow diagrams in the ERP system.
• Conduct time studies, line balancing, and capacity analyses on an as‑needed basis.
• Ensure all changes comply with AS9100D, ITAR, DFARS flow‑downs, and any other company requirements.

Basic Qualifications

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or Aerospace Engineering.
• 2-8 years of hands‑on manufacturing/process engineering experience in aerospace/defense production.
• Proven track record of cost reduction and assembly time improvement programs (e.g., part standardization, connector/harness optimization, DFM‑driven redesigns).
• Expert in GD&T (ASME Y14.5), reading complex mechanical drawings, and releasing ECNs in PLM/ERP environments (e.g., WindChill).
• Knowledge of aerospace materials, fasteners, connectors (MIL‑DTL‑38999, etc.), cable harnesses, and manufacturing processes (machining, sheet metal, composites, additive).
• U.S. citizenship and current Secret clearance (or ability to obtain/maintain one).
• Excellent communication and floor presence; comfortable presenting data‑driven recommendations to leadership and suppliers.

Preferred Qualifications

• Master’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or Aerospace Engineering.

What We Offer

• Full benefits from day one: medical, dental and vision.
• 401(k) with generous company match and immediate vesting.
• PTO and Federal holidays.

This role is based on site in either Fairfax or Manassas, Va.