Mechanical Product Development Engineer, Prototyping to Production

Torrey Holistics; Sterling (VA); On-site; USD 85,000 - 125,000; Full time

Job summary

Torrey Holistics is seeking a mechanical design Engineer to own the end-to-end hardware development cycle—from concept through production readiness—for rugged defense and dual-use systems. You will design assemblies, enclosures, and interfaces, and work closely with machinists, suppliers, and program teams to hit cost, schedule, and reliability targets.

You have 3–5 years in mechanical design, strong SolidWorks skills, hands-on prototyping, and a passion for building robust hardware in a

Qualifications

• BS in Mechanical, Mechatronics, Aerospace, Manufacturing Engineering, or related field.
• 3–5 years in mechanical design, product development, prototyping, test, or multidisciplinary hardware development.
• Strong CAD fundamentals: modeling, assemblies, materials, tolerancing, fabrication methods, structural design, DFM.
• Advanced proficiency in SolidWorks (or equivalent) with production-quality drawings including GD&T 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.

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 engineering and manufacturing processes.

Skills

Mechanical design

CAD modeling

Tolerancing

DFM

Thermal management

Electronics packaging

Cable routing

Embedded systems integration

Documentation

Problem solving

Education

BS in Mechanical/Mechatronics/Aerospace/Manufacturing Engineering or related field

Tools

SolidWorks

Onshape

Job description

Role snapshotOwn 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 responsibilitiesArchitect 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 & constraintsConstraints 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 qualificationsBS 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 experienceStartup 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 apartMechanical architecture for complex systems3D modeling and layout in SolidWorksDFM/DFA/inspection/production readinessGD&T awareness and disciplined drawing practicesMaterials, finishes, fasteners, joining, and process selectionElectronics packaging, cable routing, thermal management, integrationFixture/tooling/test equipment designPrototype assembly, instrumentation, inspection, and testingAnalytical thinking, practical judgment, attention to detail, and ownershipWorking environmentFast-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 buildsContinuous 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 & platformsCAD SoftwareMechanical Design & Engineering3D Modeling (SolidWorks)CAD Platforms: SolidWorks, Onshape