Director Plastic Design Jobs in Virginia (NOW HIRING)

At Kform, we help top defense and dual‑use startups convert breakthrough designs into producible, fieldable hardware. We cover the full stack—design, engineering, prototyping, machining, quality, and production readiness—because national security programs move in weeks, not years.

• Do you enjoy turning rough sketches and evolving CAD into tight‑tolerance parts?
• Can you jump from CAM to a manual lathe, then into an engineering conversation about DFM?
• Are you comfortable giving candid feedback on tolerances, setup, and material selection?
• Do you thrive when ownership is high, timelines are short, and quality matters?

• Machine prototype and low‑volume components for complex defense/dual‑use systems.
• Program, set up, and run CNC mills and lathes; switch to manual mills, lathes, saws, drill presses, and grinders as needed.
• Work from CAD models, drawings, sketches, notes, and verbal guidance amid evolving requirements.
• Provide actionable feedback on manufacturability, tolerances, materials, setup strategy, tool access, fixturing, finishes, and cost/lead time.
• Build/modify/repair prototypes, fixtures, tooling, test articles, brackets, enclosures, panels, mounts, and assemblies.
• Collaborate directly with engineers to move from design intent to real hardware quickly.
• Inspect parts using calipers, micrometers, indicators, height/thread gauges, and surface plates; confirm drawing, functional, and assembly needs.
• Support assembly, fit checks, test setups, and troubleshooting.
• Capture setup notes, issues, lessons learned, and design change recommendations.
• Maintain shop organization, tooling health, machine readiness, and safe practices.
• Contribute to continuous improvement across prototyping, machining, and manufacturing.

Comfortably move between:

• CNC mills and lathes
• Manual machining equipment
• CAD models and engineering drawings
• CAM toolpaths and workflows
• Inspection tools and metrology practices
• Prototype assemblies and hands‑on builds
• Fixtures, soft jaws, and custom workholding
• Technical conversations with engineers
• Production feedback and refinement

• 3–5 years in CNC/manual machining, prototype fabrication, toolmaking, model making, or similar.
• Ability to read drawings, understand design intent, and apply GD&T fundamentals.
• Hands‑on CNC mill setup and operation experience.
• Manual machining: mills, lathes, saws, drills, and standard tools.
• Knowledge of aluminum, steels, stainless, plastics, and specialty materials.
• Competence inspecting parts and applying basic quality practices.
• Comfort working from incomplete inputs and asking the right questions.
• Mechanical aptitude and practical problem‑solving.
• Safety mindset in a fast‑moving shop.
• Clear, direct communication with engineers, technicians, and production.

• Prototype/R&D, defense/aerospace, robotics, machine shop, or advanced manufacturing background.
• Programming with Fusion 360, Mastercam, SolidWorks CAM, HSMWorks, or similar CAM.
• Experience with both CNC mills and CNC lathes.
• Tight‑tolerance machining for complex assemblies.
• Fixture design, soft jaws, custom workholding, production tooling.
• Low‑volume production, engineering builds, EVT/DVT, production readiness experience.
• GD&T practice, inspection documentation, first article inspection, AS9100‑style quality.
• Exposure to sheet metal, welding, finishing/coating, additive, or assembly.
• History of improving DFM/DFA with engineers.
• Interest in manufacturing, American industry, defense technology, and hard problems.

• CNC setup/operation and real‑world machining strategy
• Manual machining and fabrication
• Drawing interpretation, tolerancing, and disciplined inspection
• CAM programming and toolpath development
• Workholding, fixturing, and setup planning
• Prototype fabrication and rapid iteration
• Materials knowledge and cutting tool selection
• DFM feedback and collaboration
• Shop organization, safety, and machine care
• Clear communication with engineers, technicians, suppliers, and production
• Ownership, judgment, and attention to detail

• CNC Mill: 3–4 axis VMC (Haas, Doosan)
• CNC Mill: 5‑axis VMC (Haas)
• CNC Lathe: 2–4 axis (Haas)
• 3D Modeling: SolidWorks
• CAD/CAM: Fusion 360, Mastercam, SolidWorks CAM/HSMWorks

• Hands‑on time with machines, tooling, materials, fixtures, prototypes, inspection equipment, and production hardware.
• Standing, walking, lifting, setup, deburring, and inspection near active manufacturing operations.
• PPE as appropriate for task, equipment, and area.
• Occasional support for customer projects, supplier coordination, testing, or production needs.

We operate on continuous improvement, aggressive value creation, and extreme ownership. We’re building the capability to bring advanced defense products into production faster. If you want to work directly with engineers, solve real manufacturing problems, and ship hardware that matters, join us.

• CNC Programming
• Design for Manufacturability (DFM)
• CNC Machine Setup & Changeover
• CAD/CAM Software