Rapid Prototype Toolmaker & Fixture Builder

Kform; Sterling (VA); On-site; USD 65,000 - 90,000; Full time

Job summary

Kform is seeking a hands-on machinist to prototype and produce low-volume parts for defense/dual-use systems. You will program, set up, and operate CNC mills and lathes, then switch to manual equipment as required, collaborating closely with engineers to validate design intent.

Ideal candidates read drawings, apply GD&T, and contribute feedback on tolerances, tooling, and material selection. Expect a fast-paced shop with continuous improvement and emphasis on quality and safety.

Qualifications

• Hands-on CNC mill setup and operation experience.
• Ability to read drawings and understand design intent, applying GD&T.
• Experience with CAM programming and toolpath development.
• Proven competence in selecting workholding and fixturing strategies.

Responsibilities

• Machine prototype and low-volume components from CAD models and drawings.
• Program, set up, and run CNC mills and lathes; switch to manual machines as needed.
• Provide feedback on manufacturability, tolerances, and materials.
• Build/modify/repair prototypes, fixtures, tooling, and assemblies.
• Collaborate with engineers to move from design intent to hardware quickly.
• Inspect parts using calipers, micrometers, indicators, and surface plates; verify drawing and assembly needs.

Skills

CNC setup/operation

Manual machining

Drawing interpretation

GD&T fundamentals

CAM programming

Workholding & fixturing

Prototype fabrication

Materials knowledge

Quality practices

Safety mindset

Clear communication with engineers

Tools

Fusion 360

Mastercam

SolidWorks CAM/HSMWorks

SolidWorks

Inspection tools & metrology

Job description

At Kform, we help top defense and dual-use startups convert breakthrough designs into producible, fieldable hardware. We cover the full stack - design, engineering, prototyping, machining, quality, and production readiness - because national security programs move in weeks, not years.

Is This You?

• Do you enjoy turning rough sketches and evolving CAD into tight-tolerance parts?
• Can you jump from CAM to a manual lathe, then into an engineering conversation about DFM?
• Are you comfortable giving candid feedback on tolerances, setup, and material selection?
• Do you thrive when ownership is high, timelines are short, and quality matters?

What You’ll Do

• Machine prototype and low-volume components for complex defense/dual-use systems.
• Program, set up, and run CNC mills and lathes; switch to manual mills, lathes, saws, drill presses, and grinders as needed.
• Work from CAD models, drawings, sketches, notes, and verbal guidance amid evolving requirements.
• Provide actionable feedback on manufacturability, tolerances, materials, setup strategy, tool access, fixturing, finishes, and cost/lead time.
• Build/modify/repair prototypes, fixtures, tooling, test articles, brackets, enclosures, panels, mounts, and assemblies.
• Collaborate directly with engineers to move from design intent to real hardware quickly.
• Inspect parts using calipers, micrometers, indicators, height/thread gauges, and surface plates; confirm drawing, functional, and assembly needs.
• Support assembly, fit checks, test setups, and troubleshooting.
• Capture setup notes, issues, lessons learned, and design change recommendations.
• Maintain shop organization, tooling health, machine readiness, and safe practices.
• Contribute to continuous improvement across prototyping, machining, and manufacturing.

How You’ll Operate

Comfortably Move Between

• CNC mills and lathes
• Manual machining equipment
• CAD models and engineering drawings
• CAM toolpaths and workflows
• Inspection tools and metrology practices
• Prototype assemblies and hands-on builds
• Fixtures, soft jaws, and custom workholding
• Technical conversations with engineers
• Production feedback and refinement

Must‑Haves

• 3-5 years in CNC/manual machining, prototype fabrication, toolmaking, model making, or similar.
• Ability to read drawings, understand design intent, and apply GD&T fundamentals.
• Hands‑on CNC mill setup and operation experience.
• Manual machining: mills, lathes, saws, drills, and standard tools.
• Knowledge of aluminum, steels, stainless, plastics, and specialty materials.
• Competence inspecting parts and applying basic quality practices.
• Comfort working from incomplete inputs and asking the right questions.
• Mechanical aptitude and practical problem-solving.
• Safety mindset in a fast-moving shop.
• Clear, direct communication with engineers, technicians, and production.

Nice‑to‑Haves

• Prototype/R&D, defense/aerospace, robotics, machine shop, or advanced manufacturing background.
• Programming with Fusion 360, Mastercam, SolidWorks CAM, HSMWorks, or similar CAM.
• Experience with both CNC mills and CNC lathes.
• Tight-tolerance machining for complex assemblies.
• Fixture design, soft jaws, custom workholding, production tooling.
• Low-volume production, engineering builds, EVT/DVT, production readiness experience.
• GD&T practice, inspection documentation, first article inspection, AS9100-style quality.
• Exposure to sheet metal, welding, finishing/coating, additive, or assembly.
• History of improving DFM/DFA with engineers.
• Interest in manufacturing, American industry, defense technology, and hard problems.

Skills That Matter

• CNC setup/operation and real‑world machining strategy
• Manual machining and fabrication
• Drawing interpretation, tolerancing, and disciplined inspection
• CAM programming and toolpath development
• Workholding, fixturing, and setup planning
• Prototype fabrication and rapid iteration
• Materials knowledge and cutting tool selection
• DFM feedback and collaborationShop organization, safety, and machine care
• Clear communication with engineers, technicians, suppliers, and production
• Ownership, judgment, and attention to detail

Tech & Machines You’ll Use

• CNC Mill: 3-4 axis VMC (Haas, Doosan)
• CNC Mill: 5-axis VMC (Haas)
• CNC Lathe: 2-4 axis (Haas)
• 3D Modeling: SolidWorks
• CAD/CAM: Fusion 360, Mastercam, SolidWorks CAM/HSMWorks

Work Environment

• Hands‑on time with machines, tooling, materials, fixtures, prototypes, inspection equipment, and production hardware.
• Standing, walking, lifting, setup, deburring, and inspection near active manufacturing operations.
• PPE as appropriate for task, equipment, and area.
• Occasional support for customer projects, supplier coordination, testing, or production needs.

Why Kform

We operate on continuous improvement, aggressive value creation, and extreme ownership. We’re building the capability to bring advanced defense products into production faster. If you want to work directly with engineers, solve real manufacturing problems, and ship hardware that matters, join us.

Core Proficiencies

• CNC Programming
• Design for Manufacturability (DFM)
• CNC Machine Setup & Changeover
• CAD/CAM Software