Rugged Defense Mechanical Engineer: Prototype to Production

Kform; Sterling (VA); On-site; USD 90,000 - 120,000; Full time

Job summary

Kform is seeking a mechanical engineer to design, prototype, test, and drive production readiness of rugged hardware for defense and dual-use customers. You will work across mechanical, electrical, software, manufacturing, and quality to deliver production-ready components with strong design discipline.

You’ll prototype quickly, document thoroughly, and collaborate with machinists, vendors, and production teams to close the loop from concept to fielded hardware.

Qualifications

• Bachelor’s degree in Mechanical Engineering or related field.
• 3–5 years of mechanical design, product development, prototyping, or related hardware experience.
• Strong fundamentals: CAD modeling, mechanical assemblies, materials, tolerancing, fabrication methods, structural design, DFM.
• Advanced proficiency in SolidWorks or equivalent.
• Ability to produce production-quality drawings with clear dimensions and revision control.
• Hands-on experience with rapid prototyping, fabrication tools, shop equipment, inspection and test equipment.
• Working knowledge of electronics packaging, thermal management, and system integration.
• Ability to document engineering work clearly, including revisions and test results.
• Strong problem-solving and independent work capability with multidisciplinary teamwork.

Responsibilities

• Lead the mechanical design and development of complex hardware products, including mechanical assemblies, enclosures, ruggedized systems, and fixtures.
• Create detailed mechanical designs, drawings, assemblies, and documentation in SolidWorks.
• Translate customer requirements and constraints into practical mechanical designs.
• Collaborate across mechanical, electrical, software, manufacturing, and quality domains.
• Design around constraints: packaging, weight, thermal, environmental exposure, shock, EMI, assembly, serviceability, cost, lead time.
• Prototype proof‑of‑concept designs and iterate with hands‑on testing.
• Build, assemble, inspect, and troubleshoot prototypes and production‑intent hardware.
• Plan and execute testing for fit, structural performance, durability, thermal behavior, manufacturability, assembly, safety.
• Analyze test results, identify failure modes, and drive design improvements.
• Maintain engineering docs: CAD models, drawings, BOMs, revision history, test results, design rationale.
• Collaborate with manufacturing, quality, supply chain, and program teams.

Skills

Mechanical design

3D modeling

SolidWorks

Multidisciplinary coordination

Prototype fabrication

Education

Bachelor's degree in Mechanical Engineering

Tools

Onshape

Fabrication tools

Inspection tools

Job description

Kform is seeking a mechanical engineer to design, prototype, test, and drive production readiness of rugged hardware for defense and dual-use customers. You will work across mechanical, electrical, software, manufacturing, and quality to deliver production-ready components with strong design discipline.

You’ll prototype quickly, document thoroughly, and collaborate with machinists, vendors, and production teams to close the loop from concept to fielded hardware.