Mechanical Design Engineer

ABOUT THE TEAM

You will join an agile, multidisciplinary engineering team dedicated to bringing next-generation autonomous flight systems from concept to operational deployment. Working at the intersection of design engineering and manufacturing, our team collaborates daily with Stress, Systems, and Flight Test specialists to iterate at rapid pace. In this environment, you will bridge the gap between digital modeling and the factory floor, ensuring our platforms transition smoothly from initial prototypes into high-rate production.

YOUR MISSION

As a Mechanical Design Engineer at STARK, you will serve as a key contributor to the mechanical architecture of our next-generation UAV platforms. You will take critical subsystems from initial concept through to high-rate production, working closely with our manufacturing facilities to ensure our airframes are robust, cost-effective, and mission-ready.

WHAT YOU WILL DO AT STARK

• Own the mechanical design of major assemblies and payload integrations across current and future UAV platforms.

• Optimise designs for high-rate production to scale platforms seamlessly from prototype to hundreds of units without quality degradation.

• Apply advanced parametric modeling, GD&T, and tolerance stack-up analysis to ensure first-time-right assembly on the factory floor.

• Drive material selection, structural layouts, and manufacturing processes with an emphasis on composites, additive manufacturing, and machining.

• Collaborate with Stress, Flight Test, and Systems teams to validate structural integrity and support successful flight trials.

• Execute hands-on rapid prototyping, CAD iterations, and shop-floor troubleshooting to solve manufacturing bottlenecks at pace.

WHAT YOU BRING TO THE MISSION

• Professional experience in mechanical design within aerospace, UAVs, automotive, light aircraft, or autonomous systems.

• Proven track record of taking structural parts and assemblies from initial sketch through verification and into full production.

• High proficiency in SolidWorks for complex 3D parametric modeling and drafting.

• Strong working knowledge of manufacturing processes, including composites, 3D printing, CNC machining, and injection moulding.

• Clear technical communication skills with the ability to articulate trade-offs to engineering peers and programme leadership.

• Eligibility for UK Security Clearance (SC).

NICE TO HAVE

• Experience using CATIA for advanced surface modeling or aerospace assemblies.

• Familiarity with MIL standards and military/civil aerospace certification pathways.

ARMED FORCES COMMITMENT:

We are proud to hold the Bronze Award from the Defence Employer Recognition Scheme (ERS), reflecting our meaningful commitment and ongoing support for UK defence personnel. At our core, we believe in championing those who serve, those who have served, and their families. As part of this scheme, we are dedicated to providing an inclusive, supportive environment where members of the Armed Forces community can thrive and bring their invaluable skills to our team.