Mechanical Engineer - Manufacturing Support

Mechanical Engineer – Manufacturing Support

Chantilly, VA | $68–$71/hour | Long-Term Contract-to-Hire

Position Overview

We are seeking a hands-on Mechanical Engineer to support the manufacturing, assembly, integration, and continuous improvement of ruggedized server systems used in aerospace and defense applications.This role focuses on providing day-to-day mechanical engineering support to manufacturing operations, troubleshooting production challenges, and developing practical design solutions to keep production moving. You will work closely with manufacturing, electrical, structural, and systems engineering teams to resolve mechanical issues, improve assembly processes, and integrate commercial off-the-shelf (COTS) components into specialized server systems.The ideal candidate has a strong mechanical engineering foundation, CAD design experience, and the ability to move between engineering design work and hands-on production support. Success in this position requires someone who is detail-oriented, adaptable, collaborative, and comfortable responding to changing priorities and time-sensitive manufacturing needs.

Key Responsibilities

1. Manufacturing Engineering & Production Support

• Provide hands-on mechanical engineering support throughout manufacturing, assembly, and system integration.
• Troubleshoot mechanical design issues, assembly challenges, and production-related problems.
• Work directly with manufacturing technicians and production personnel to identify issues and implement practical solutions.
• Assist with mechanical debugging, component fitment, assembly modifications, and production improvements.
• Identify opportunities to improve manufacturing efficiency, product quality, and assembly processes.
• Respond to urgent production needs while balancing multiple engineering priorities.

2. Mechanical Design & CAD Development

• Create, modify, and improve mechanical designs for ruggedized server systems and electromechanical assemblies.
• Develop mechanical components, mounting brackets, support structures, and cooling solutions for COTS hardware.
• Utilize CAD software to create and update 3D models, mechanical assemblies, and engineering drawings.
• Evaluate designs for manufacturability, accessibility, reliability, and ease of assembly.
• Support engineering changes and design modifications based on production feedback and identified issues.

3. Mechanical Integration & Troubleshooting

• Support the integration of rackmount servers, PCBs, cable assemblies, cooling systems, and other electromechanical components.
• Work alongside electrical, structural, and systems engineers to resolve mechanical interface and integration challenges.
• Identify component clearance, mounting, fitment, thermal management, and assembly issues.
• Apply mechanical engineering principles to develop solutions that improve system functionality and reliability.
• Assist with hands-on evaluation and debugging of mechanical assemblies.

4. Engineering Documentation & Quality

• Review and maintain mechanical drawings, specifications, engineering changes, and technical documentation.
• Ensure designs and manufacturing processes meet applicable engineering specifications and quality requirements.
• Document troubleshooting activities, design modifications, and corrective actions.
• Support root cause investigations and continuous improvement initiatives.
• Verify that mechanical designs meet functional, manufacturing, and reliability requirements.

5. Production Coordination & Continuous Improvement

• Partner with production leads, engineering teams, and project stakeholders to prioritize manufacturing issues.
• Participate in Tier/Gemba Board meetings to review production challenges, track action items, and drive resolution.
• Evaluate competing priorities and determine the most effective approach to resolving production issues.
• Communicate engineering recommendations and provide timely updates to production stakeholders.
• Maintain a flexible, solutions-oriented approach in a fast-paced manufacturing environment.

Required Qualifications

• Bachelor's degree in Mechanical Engineering or a related engineering discipline, or equivalent relevant industry experience.
• Previous experience in mechanical engineering, manufacturing support, or mechanical design.
• Experience supporting manufacturing or assembly operations and troubleshooting mechanical issues.
• Proficiency with CAD software such as SolidWorks, CATIA, AutoCAD, or similar platforms.
• Ability to read, interpret, and modify mechanical drawings and engineering specifications.
• Strong understanding of mechanical design principles, materials, and manufacturing processes.
• Experience working with cross-functional engineering and manufacturing teams.
• Strong analytical, troubleshooting, and problem-solving abilities.
• Excellent attention to detail and the ability to manage shifting priorities.

Preferred Qualifications

• Aerospace, defense, military, or ruggedized electronics manufacturing experience.
• Experience designing or supporting ruggedized computing systems, rackmount servers, or electromechanical assemblies.
• Familiarity with COTS hardware integration.
• Experience with PCB mounting, cable routing, thermal management, cooling systems, and mechanical support structures.
• Hands-on experience with mechanical assembly, debugging, and production troubleshooting.
• Knowledge of Design for Manufacturability (DFM) and continuous improvement practices.
• Familiarity with Tier/Gemba production management processes.

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