Principal / Senior Mechanical Design Engineer (All Genders)

About Us STARK is a new kind of defence technology company revolutionizing the way autonomous systems are deployed across multiple domains. We design, develop and manufacture high performance unmanned systems that are software-defined, mass-scalable, and cost effective. This provides our operators with a decisive edge in highly contested environments.

We’re focused on delivering deployable, high-performance systems - not future promises. In a time of rising threats, STARK is bolstering the technological edge of NATO Allies and their Partners to deter aggression and defend Europe - today. Your mission

As our Senior Mechanical Design Engineer, you will own the mechanical architecture of STARK’s next-generation UAV platforms from concept to high-rate production. You will set technical direction, mentor engineers, and work closely with cross-functional teams to deliver highly reliable, certifiable, and field-deployable systems under aggressive timelines.

You will both define mechanical design strategy and dive deep into CAD, tolerance stacks, and Design for Manufacture/Assembly (DFMA) prototypes. You will act as the company’s authority on mechanical design for airframes and payload integration, influencing platform-level decisions and ensuring designs are robust, scalable, cost-effective for mass production, and certifiable.

Responsibilities

• Lead mechanical design for UK current and future UAV platforms
• Define and enforce best practices for parametric modeling, GD&T, and tolerance stack-ups
• Drive airframe material selection, structural layout, and manufacturability decisions
• Oversee supplier engagement for structural components, composites, and assemblies
  Collaborate with stress, flight test, and systems teams to ensure structural integrity
• Support and occasionally lead design reviews with leadership, partners, and certifying authorities
• Lead mechanical design for UK current and future UAV platforms, focusing on design-for-manufacture (DFM) and high-rate production methods
• Define and enforce best practices for parametric modeling, GD&T, and tolerance stack-ups, with an emphasis on production efficiency
• Collaborate with stress, flight test, and systems teams to ensure structural integrity while optimising designs for mass production
• Support and occasionally lead design reviews with leadership, partners, and certifying authorities, presenting trade-offs for production scale
• Be hands-on with CAD (SolidWorks/CATIA), prototyping, and shop-floor troubleshooting, with a focus on process and design optimization for rate increase

Qualifications

• Mechanical design experience, in ideally in aerospace / UAV / autonomous systems

• Proven record of taking structures from concept through verification to high rate production (wing, fuselage, empennage)

• Expert in SolidWorks (CATIA V5/V6 a plus) and tolerance stack analysis

• Strong knowledge of composites, 3D printing, machining, injection moulding, and joining methods

• Familiarity with MIL standards and EASA/FAA certification pathways (SC-Light UAS, CS-23)

• Excellent communication skills - able to influence at exec and program level

• Eligible for UK Security Clearance

Our Commitment to the Armed Forces Community

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.