Kform · 5 hours ago
Mechanical Design Engineer
Sterling, VA
Full-time
Onsite
Mid, Senior Level
3+ years expKform is a leader in transforming innovative technology for defense applications, seeking a Design Engineer II — Mechanical / Firearms. The role involves leading mechanical design, prototyping, and validation of firearms-adjacent products, ensuring quality and efficiency in a phase-gated product development environment.
ConsultingInternet of ThingsManufacturingProduct DesignSensor
No H1B
U.S. Citizen OnlyHiring Manager
Tim Winkler
Responsibilities
Own mechanical design from concept through detailed design and release using SolidWorks; deliver robust models, drawings, and GD&T suitable for production
Engineer firearms-like and firearms-adjacent systems (mounts, enclosures, interfaces, recoil/impact management, ergonomics, accessory integration)
Perform tolerance stacks, material and fastening selection, DFM/DFA, and durability analysis (hand-calcs and FEA-driven trade studies)
Lead prototype builds (machined, sheet metal, polymer, additive), fixtures, and test rigs; drive rapid iteration using empirical test data
Conduct structured verification & validation: author test plans, execute EVT/DVT builds, analyze results, and manage ECR/ECOs to closure
Translate user stories into measurable requirements (PRD); produce integration artifacts (e.g., ICDs) and complete release packages
Collaborate with manufacturing, supply chain, and quality to industrialize designs; support pilot runs, PFMEAs, and process capability work
Interface with electronics/firmware teams when needed (no coding/ECAD required) to ensure mechanical accommodation and reliability
Mentor Design Engineer I and technicians; model best-in-class design hygiene, documentation, and shop safety
Execute in both sprint-based “Build” work and phase-based “Scale” programs, maintaining schedule and deliverable discipline
Qualification
Required
B.S. in Mechanical Engineering or related field
3–7 years of mechanical product development with released, manufactured hardware
Expert SolidWorks user (surfacing, complex assemblies, configurations, PDM); strong drawing control and GD&T
Proven DFM/DFA across metals (machining, sheet, casting), polymers, and additive; hands-on prototype experience
Demonstrated experience with firearms platforms at the engineering/armorer level (mechanisms, interfaces, safety, ergonomics)
Competence in test planning, failure analysis, and closing corrective actions (ECR/ECO)
Mechanism design, kinematics, tolerance stacks, fastener engineering, and fatigue/fracture awareness
Shop-forward mindset: can build jigs/fixtures, assemble prototypes, and instrument tests safely and efficiently
Clear technical communication; crisp documentation; strong ownership in cross-functional settings
Systems thinking with disciplined risk management (DFMEA/PFMEA) and data-driven decision-making
Professional familiarity with electronics as a mechanical integration concern (bonus, not required)
Alignment with Kform core values and commitment to continual improvement
U.S. person status for ITAR-controlled work; ability to pass background checks
Willingness to flex to meet program milestones across Kform's Build and Scale engagements
Preferred
Defense, rugged electronics packaging, or similarly regulated environments; familiarity with MIL-STD-810/461, DO-160, TEMPEST interfaces
Background integrating optics, rails, grips, stocks, magazines, triggers, safeties, and accessory interfaces; knowledge of recoil dynamics
FEA (static, modal, thermal) and tolerance analysis tools; basic metrology/CMM workflows
Exposure to coatings and finishes (anodize, conversion coat, Cerakote, powder/wet paint) and polymer/overmold design
Experience with phase-gated development (PRD, ICD, EVT/DVT) and manufacturing transfer
Company
Kform
Designs and manufactures defense systems, collaborating with innovative startups and leading corporations to deliver solutions.
11-50 employees
Funding
Current Stage
Early StageLeadership Team
Callye Keen
Chief Executive Officer
Recent News
2022-02-10
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