Rugged Systems Mechanical Engineer and Prototyping

Torrey Holistics; Sterling (VA); On-site; USD 95,000 - 130,000; Full time

Job summary

Kform is seeking a hands-on mechanical engineer to lead design of ruggedized systems, brackets, and tooling. You’ll drive rapid prototyping, testing, and validation of hardware ready for production while coordinating with manufacturing, quality, and supply chain to meet stringent field test windows.

You will design with weight, thermal, EMI, and environmental constraints in mind, delivering complete drawings, BOMs, and revision history for fast, reliable builds.

Qualifications

• Bachelor’s degree in Mechanical, Mechatronics, Aerospace, Manufacturing Engineering, or related.
• 3–5 years in mechanical design, product development, prototyping, test, manufacturing engineering, or multidisciplinary hardware development.
• Fluency in SolidWorks (or similar) and production-quality drawings (dimensions, tolerances/GD&T, notes, finishes, revision control).
• Strong fundamentals: CAD modeling; assemblies; materials; tolerancing; fabrication methods; structural design; DFM.
• Hands-on with rapid prototyping, shop equipment, inspection and test tools, and physical hardware.
• Working knowledge of electronics packaging, cable routing, thermal management, embedded integration, manufacturing, quality, test, and systems integration.

Responsibilities

• Lead mechanical design for products that include assemblies, ruggedized systems, brackets/mounts/panels/structural components, mechanisms/interfaces, thermal solutions, fixtures/tooling, test equipment, and production-ready parts.
• Turn customer needs and environmental realities into manufacturable designs with complete drawings, BOMs, and revision control.
• Prototype quickly; assemble, instrument, inspect, and troubleshoot real hardware.
• Plan and execute validation for fit/function, structural and durability performance, thermal behavior, manufacturability, assembly processes, and safety/reliability.
• Design within constraints: packaging, weight, thermal, environmental exposure, shock/vibration, EMI/shielding, assembly sequence, serviceability, cost, and lead time.
• Work across electrical, embedded, manufacturing, quality, test, supply chain, and program teams to optimize the whole system.
• Document thoroughly: CAD, drawings, BOMs, change history, assembly instructions, test data, design rationale, and trade studies.
• Partner directly with machinists, fabricators, vendors, and production to ensure intent matches output.
• Mentor junior engineers and independently drive small projects from ambiguous input to delivered hardware.

Skills

Strong CAD modeling

Tolerancing & GD&T

System-level mechanical design

Rapid prototyping & testing

Cross-functional collaboration

Education

Bachelor’s in Mechanical Engineering

Tools

SolidWorks

Onshape

Job description

Kform is seeking a hands-on mechanical engineer to lead design of ruggedized systems, brackets, and tooling. You’ll drive rapid prototyping, testing, and validation of hardware ready for production while coordinating with manufacturing, quality, and supply chain to meet stringent field test windows.

You will design with weight, thermal, EMI, and environmental constraints in mind, delivering complete drawings, BOMs, and revision history for fast, reliable builds.