Manufacturing Engineer Jobs in Reston, VA (NOW HIRING)

This role focuses on driving the design, development, and improvement of low-volume, high-reliability manufactured systems. The Manufacturing Engineer applies design for manufacturability principles, collaborates closely with suppliers and internal engineering teams, and troubleshoots complex manufacturing processes to ensure products meet stringent technical, quality, and regulatory requirements. The position blends hands-on process and manufacturing engineering with mechanical systems design, CAD modeling, and adherence to industry codes and standards in highly regulated, high-precision environments.

Responsibilities

• Apply manufacturing engineering expertise to low-volume, complex production environments, ensuring that products and systems meet high reliability and precision requirements.
• Influence and drive the design and development of mechanical systems with a strong focus on Design for Manufacturing (DFM), Design for Assembly (DFA), and Design for X (DFX).
• Develop mechanical and physical concepts and support the development of manufacturing processes for structures, systems, and components used in high reliability products or facilities.
• Identify, collect, and document applicable requirements, interfaces, design basis, and design criteria by coordinating with key stakeholders and systems engineers.
• Support the identification and application of relevant industry codes and standards under the direction of project leads and systems engineers.
• Plan and perform analyses of mechanical systems and manufacturing processes to confirm they can perform intended functions and meet technical specifications and design requirements.
• Perform hand calculations and use analytical tools to conduct structural, thermal, hydraulic, and other scoping calculations as required by project leads and systems engineers.
• Support mechanical components and systems design, including developing innovative mechanical solutions for pressure vessels, piping, system internals, and high-temperature materials such as graphite.
• Integrate design activities across internal engineering team members, external partners, and suppliers, ensuring design features meet requirements using consensus codes and standards.
• Create and maintain CAD-generated engineering models and drawings of complex systems, with a focus on accurate modeling for manufacturing and assembly.
• Assess complex systems for manufacturability, assembly, and integration considerations, providing input to improve production readiness and reduce risk.
• Support process improvement initiatives, tooling development, fabrication methods, and lean manufacturing practices to enhance quality and efficiency.
• Contribute to welding-related design and manufacturing activities, including weldments and weld engineering considerations, in alignment with applicable welding standards.
• Write and develop design documentation such as design basis documents, technical reports, calculations, and drawings in accordance with established procedures.
• Develop Verification and Validation (V&V) plans for analytical tools and support the qualification and ongoing improvement of the engineering toolset.
• Perform work in accordance with company quality procedures for design and configuration management to ensure project quality requirements are consistently met.
• Provide independent reviews and acceptance reviews of engineering deliverables and data to verify accuracy, completeness, and compliance with requirements.
• Collaborate with outside vendors and suppliers to address manufacturing quality concerns, troubleshoot production issues, and incorporate manufacturer feedback into designs.
• Troubleshoot manufacturing issues in real time, providing technical solutions to production challenges, particularly for high-temperature metallic alloys and high-pressure systems.
• Travel domestically and internationally several times per year, as needed, to vendor and partner sites to support manufacturing startup, follow-up on first-of-a-kind components, and oversee production and testing activities.

• Bachelor’s degree in engineering, aerospace, mechanical engineering, or a related technical discipline.
• At least 10–15 years of relevant industry experience in manufacturing engineering, process engineering, or related fields.
• Proven experience performing manufacturing engineering tasks in larger, complex, low-volume production environments.
• Strong background in Design for Manufacturing (DFM), Design for Assembly (DFA), and/or Design for X (DFX) for high-reliability systems and products.
• Experience in mechanical systems design and development, including taking products through manufacturing and testing oversight.
• Proficiency with 3D CAD programs for mechanical design and drawing creation (experience with NX is preferred).
• Experience using a Product Data Management System (PDMS) or Product Lifecycle Management (PLM) system, such as Windchill or similar configuration management tools.
• Demonstrated ability to work with outside vendors and suppliers on manufacturing quality, process issues, and design feedback.
• Experience with machining and assembly, particularly for high-temperature metallic alloys or high-pressure systems.
• Ability to perform engineering analyses using hand calculations and analytical tools for structural, thermal, hydraulic, and other scoping calculations.
• Experience assessing manufacturability, assembly, and integration considerations for complex mechanical systems.
• Familiarity with highly regulated, high-precision industries such as nuclear, aerospace, power generation, or medical devices.
• Strong written communication skills for preparing technical reports, design basis documents, calculations, and engineering drawings.
• Willingness and ability to travel domestically and internationally up to several times per year, including occasional trips of up to a week in duration.

• Master’s degree in engineering or a related technical discipline is a plus.
• Experience in a heavy manufacturing startup environment, including startup and follow activities for first-of-a-kind (FOAK) components.
• background in weld engineering, with a welding-related degree preferred.
• Familiarity with AWS welding standards and ASME Boiler and Pressure Vessel Code (BPVC) Section IX.
• Experience with ASME component manufacturing, preferably to ASME BPVC Section III, or at minimum Section VIII.
• Proficiency in Non-Destructive Examination (NDE) techniques applicable to nuclear or similar high-reliability components.
• Ability to guide designs to accommodate NDE accessibility constraints, including spatial limitations.
• Experience with pressure vessel design, fabrication, and related manufacturing processes.
• Knowledge of tooling design, fabrication processes, and lean manufacturing principles.
• Experience working with high-temperature materials such as graphite and related system internals.
• Strong problem-solving skills for troubleshooting manufacturing issues and implementing practical technical solutions.
• Experience in process improvement initiatives in high-precision, highly regulated environments.
• Comfort working within formal quality, design, and configuration management procedures.

The role is based in a professional office environment with close collaboration among multidisciplinary engineering teams, suppliers, and partners. Work involves extensive use of modern engineering tools, including 3D CAD software (such as NX), PDMS/PLM systems (such as Windchill or similar), and analytical tools for structural, thermal, and hydraulic calculations. The position supports manufacturing activities for complex, high-reliability components, often in highly regulated industries such as nuclear, aerospace, power generation, or medical. Occasional domestic and international travel to vendor and partner facilities is required, including visits to fabrication, machining, and assembly sites to support manufacturing startup, troubleshooting, and oversight. The company offers a growing environment with significant opportunities for professional advancement and long-term career development.

Job Type & Location

This is a Contract to Hire position based out of Rockville, MD.

The pay range for this position is $70.00 - $90.00/hr.

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)

This is a fully onsite position in Rockville,MD.

This position is anticipated to close on Jun 26, 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 actalentaccommodation@actalentservices.com 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.