Mechanical Product Development Engineer, Prototyping to Production

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

• 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.

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 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.

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 systems
• 3D modeling and layout in SolidWorks
• DFM/DFA/inspection/production readiness
• GD&T awareness and disciplined drawing practices
• Materials, finishes, fasteners, joining, and process selection
• Electronics packaging, cable routing, thermal management, integration
• Fixture/tooling/test equipment design
• Prototype assembly, instrumentation, inspection, and testing
• Analytical thinking, practical judgment, attention to detail, and ownership

Working environment

• Fast-paced development and manufacturing setting with frequent hands-on work.
• Expect standing, walking, assembling, testing, troubleshooting, inspecting, and working near active operations.
• PPE used as required by task and area.
• Occasional travel to customers, suppliers, testing, and program needs.

How Kform builds

Continuous improvement, aggressive value creation, and extreme ownership drive our work. We compress the path from concept to fielded hardware by sweating details, respecting customers, understanding real-world constraints, and executing. Join us if you want full-cycle product exposure and the chance to build hardware that matters.

Tools & platforms

• CAD Software
• Mechanical Design & Engineering
• 3D Modeling (SolidWorks)
• CAD Platforms: SolidWorks, Onshape