Senior Mechanical Engineer

CoAspire is a cutting-edge defense manufacturing leader in Northern Virginia, specializing in the precision assembly of advanced weapons systems. With over thirteen years of a legacy of innovation, we're at the forefront of building reliable, affordable mass weapons that protect and empower our nation’s warfighters. Our tight-knit team thrives in a collaborative environment where safety, quality, and work-life balance come first with a focus on professional growth at our new 27,000+ sq. ft. facility. Join us to make a tangible impact on mission-critical technology while enjoying Northern Virginia's vibrant community. What you will do: You will work out of either our Headquarters in Fairfax, VA or our production facility in Manassas, VA to drive assembly process optimization, cost reduction, and design-for-manufacturability improvements for weapon systems. You will identify and implement changes to mechanical parts, connectors, fasteners, harnesses, brackets, and subsystems to dramatically reduce build time, lower material costs, eliminate production bottlenecks, and support affordable high-rate manufacturing — all while maintaining full compliance with government performance, quality, and safety standards. This hands-on role works side-by-side with technicians, quality, procurement, and design engineering to transition products from prototype/design models to sustained high-volume production. Responsibilities: Lead Design-for-Manufacturing/Assembly (DFM/DFA) reviews and value engineering initiatives to simplify mechanical designs, standardize components, and reduce part count/SKU proliferation. Identify and qualify lower-cost alternative parts, connectors, cables, fasteners, and materials (COTS/MIL SPEC) that meet form/fit/function, environmental, and ITAR requirements while achieving reduced cost savings. Optimize assembly sequences, tooling, fixtures, and work instructions to cut assembly time, reduce labor hours, and improve first-pass yield on the production line. Perform root-cause analysis on production issues (fit issues, non-conformances, rework) and implement corrective actions, including ECNs and drawing updates. Collaborate with supply chain and suppliers on make-vs-buy decisions, vendor qualifications, and long-term agreements to secure cost-effective, reliable sources. Support and contribute to manufacturing bills of materials (MBOMs), routings, and process flow diagrams in the ERP system. Conduct time studies, line balancing, and capacity analyses on an as needed; mentor technicians and junior engineers on the floor. Ensure all changes comply with AS9100D, ITAR, DFARS flow-downs, and any other company requirements. Basic Qualifications: Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or Aerospace Engineering. 8+ years of hands-on manufacturing/process engineering experience in aerospace/defense production. Proven track record of cost reduction and assembly time improvement programs (e.g., part standardization, connector/harness optimization, DFM-driven redesigns). Expert in GD&T (ASME Y14.5), reading complex mechanical drawings, and releasing ECNs in PLM/ERP environments (e.g., WindChill). Strong knowledge of aerospace materials, fasteners, connectors (MIL-DTL-38999, etc.), cable harnesses, and manufacturing processes (machining, sheet metal, composites, additive). Excellent communication and floor presence; comfortable presenting data-driven recommendations to leadership and suppliers. U.S. citizenship and current Secret clearance (or ability to obtain/maintain one). Preferred Qualifications: Master’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or Aerospace Engineering. What We Offer: Beyond competitive pay, we offer: Full benefits beginning first of month following hire: medical, dental and vision 401(k) with generous company match and immediate vesting PTO and Federal holidays The anticipated salary range for this position is $145,000-$200,000. Actual compensation will be determined based on experience, skills, qualifications, and internal equity. Apply now! We're reviewing applications on a rolling basis. Let's build the future together. No agencies, please. This role is based on site in either Fairfax or Manassas, Va. #Hiring #DefenseTech #ManassasVA #AerospaceCareers