Mechanical Engineer

Mechanical Engineer | 5-days onsite in Sterling, VA | Pay: $45 - $60/hr | 12-month contract-to-hire
Job Description
Join a multidisciplinary engineering team designing, fabricating, testing, and deploying prototypes for counterunmanned aircraft systems (cUAS) technology. As a Mechanical Engineer, you will own mechanical designs that directly contribute to nextgeneration airspace defense systems, taking concepts from initial idea through production release. You will collaborate closely with electrical, software, systems, manufacturing, and product teams to deliver rugged, reliable hardware solutions that operate in demanding realworld environments.
Responsibilities

• Design and develop mechanical components, assemblies, and enclosures for advanced airspace defense systems.
• Drive product development activities from concept generation through testing, validation, and manufacturing release.
• Create detailed 3D CAD models, drawings, and design documentation using tools such as SolidWorks, Fusion 360, AutoCAD, or similar platforms.
• Design a wide range of hardware including sheet metal components, welded structures, machined parts, injection molded components, and environmental enclosures.
• Build, assemble, and evaluate prototype hardware to validate design concepts and overall system performance.
• Develop and execute test plans to assess functionality, durability, and environmental reliability of mechanical designs.
• Collaborate crossfunctionally with electrical engineers, systems engineers, product managers, manufacturing partners, and field teams to ensure cohesive system integration.
• Support system integration efforts and actively contribute to design reviews throughout the product lifecycle.
• Identify technical risks and implement creative, practical solutions to complex engineering challenges.
• Maintain thorough documentation, specifications, and engineering change records to ensure traceability and quality.
• Contribute to continuous improvement initiatives focused on product quality, manufacturability, and cost optimization.
• Allocate time across key activities, including approximately 30% CAD design and documentation, 30% crossfunctional collaboration and engineering reviews, 30% handson prototyping, fabrication, testing, and validation, and 10% rapidresponse engineering support and problem solving.

Essential Skills

• Bachelor's degree in Mechanical Engineering or a closely related engineering discipline.
• 05 years of professional mechanical engineering experience.
• Proficiency with CAD software such as SolidWorks, AutoCAD, Fusion 360, or similar platforms.
• Experience creating engineering drawings and design documentation suitable for manufacturing and production.
• Ability to work with fabrication and prototyping processes, including basic handson build and test activities.
• Eligibility to obtain a US Secret Clearance.
• Ability to travel up to 10% of the time as project needs require.
• Strong analytical and problemsolving skills applied to mechanical design and system performance.
• Effective communication skills for collaborating with crossfunctional engineering and product teams.
• Attention to detail and commitment to maintaining accurate technical documentation and records.

Additional Skills & Qualifications

• Experience designing and releasing mechanical products into production environments.
• Handson prototyping experience using fabrication tools, machine shop equipment, or 3D printers.
• Experience with sheet metal design, weldments, machined components, injection molded plastics, or ruggedized mechanical enclosures.
• Familiarity with embedded systems, microcontrollers, or electromechanical systems and their mechanical integration.
• Experience designing hardware for harsh environmental conditions, including outdoor or industrial use.
• Knowledge of shock, vibration, thermal management, EMI/EMC, or environmental sealing considerations in mechanical design.
• Experience working with military, aerospace, defense, industrial, robotics, or outdoor hardware systems.
• Familiarity with MILSTDs and environmental qualification testing processes.
• Experience with FEA, CFD, or other simulation tools to analyze structural and thermal performance.
• Understanding of GD&T (Geometric Dimensioning and Tolerancing) for precise manufacturing specifications.
• Experience in new product development, including iterative design, prototyping, and validation cycles.
• Ability to identify design tradeoffs related to cost, manufacturability, and reliability, and to optimize accordingly.

Work Environment
This role is based in Sterling, VA, with a hybrid schedule that includes four days per week onsite (Tuesday through Friday) and the option to work remotely on Mondays. You will work in a cuttingedge facility that includes multiple onsite labs dedicated to prototyping, testing, and system integration of advanced cUAS hardware. The environment is highly collaborative and fastpaced, with regular interaction among mechanical, electrical, software, systems, and product teams. You will use modern CAD and simulation tools, as well as fabrication and test equipment, to develop rugged hardware deployed in realworld operational settings. The work supports critical missions for military and public safety organizations, including efforts to protect major global events and enhance security in complex environments.
Job Type & Location
This is a Contract to Hire position based out of Sterling, VA.
Pay and Benefits
The pay range for this position is $45.00 - $60.00/hr.
Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.
Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following: Medical, dental & vision Critical Illness, Accident, and Hospital 401(k) Retirement Plan Pre-tax and Roth post-tax contributions available Life Insurance (Voluntary Life & AD&D for the employee and dependents) Short and long-term disability Health Spending Account (HSA) Transportation benefits Employee Assistance Program Time Off/Leave (PTO, Vacation or Sick Leave)
Workplace Type
This is a hybrid position in Sterling,VA.
Application Deadline
This position is anticipated to close on Oct 13, 2026.
About Actalent


Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.


The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.


If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email View email address on click.appcast.io for other accommodation options.



San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.



Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.



Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.