Mechanical Design Engineer (All Genders)

STARK

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.

STARK

ABOUT US STARK is a new kind of defence technology company revolutionising 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 are 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 You will be the systems safety lead for a next-generation Unmanned Aerial System (UAS), driving a safety-by-design approach across the entire product lifecycle. This includes ensuring all mechanical, electrical, and software subsystems meet stringent safety requirements. As a Principal / Senior Systems Engineer, you will define the safety-critical architecture and interfaces, manage safety integration and verification activities, and drive system safety validation through rigorous testing, hazard analysis, and compliance reporting. RESPONSIBILITIES * Serve as the system safety lead for UAS product development and upgrades, owning overall platform safety and coherency from concept through delivery. * Work day-to-day within multidisciplinary teams (mechanical, electrical, avionics, software, test) across the full lifecycle of UAS design, integration, test and fielding. * Conceptualise and capture system architecture for new platforms and enhancements, producing technical trade studies, safety-critical sizing, and system performance assessments. * Establish and execute the system safety program, including the development of Preliminary Hazard Analyses (PHA) and System/Subsystem Hazard Assessments (SHA/SSHA). * Lead and coordinate Failure Mode and Effects Analysis (FMEA) and Design Failure Mode and Effects Analysis (DFMEA) activities across multidisciplinary teams. * Produce layout and system design plans, define Interface Control Documents (ICDs) and enforce interface control processes for mechanical, electrical, and software subsystems. * Establish and maintain requirements baselines, including safety requirements, and traceability using industry tools (e.g., IBM DOORS) and MBSE approaches. * Implement robust change control processes to manage and assess the impact of all design changes on system safety and compliance. * Act as the technical interface between internal teams, suppliers and customers to coordinate payload integration, unique/custom hardware or software interfaces, and ensure on-time capability delivery. * Manage tactical engineering tasks during development sprints and test campaigns, resolving cross-discipline issues and maintaining configuration control. QUALIFICATIONS * Degree (or equivalent) in Systems, Aerospace, Electrical or a closely related Engineering discipline. * Significant industry experience with demonstrable systems engineering and system safety responsibility on UAV/aerospace or equivalent complex, safety-critical platforms. * Strong practical experience integrating complex systems: power systems, RF/EMC, EO sensors, networking, flight controllers and payload interfaces. * Proven track record in requirements capture, compliance analysis, and verification/validation activities; proficient with requirements management tools (IBM DOORS or similar). * Demonstrable experience leading and executing safety analyses, including Hazard Assessments (PHA/SHA/SSHA) and FMEA/DFMEA. * Familiarity with safety standards (e.g., ARP4754A, ARP4761, DO-178C, DO-254) and the principles of requirements and change control in a regulated environment. * Familiarity with MBSE principles, interface control processes and configuration management in regulated environments. * Excellent written and verbal communication skills; highly organised and detail-oriented. * Ability to operate effectively in fast-moving, ambiguous environments and to travel within the UK/Europe for testing and integration. * A genuine passion for system development, integration and testing and a collaborative, inclusive team approach. * Security-cleared or eligible to obtain UK defence clearance. Desirable * Prior experience leading Systems Engineering and authoring safety assurance documentation and risk management artefacts. * Experience integrating complex/custom payloads for partner or customer use (hardware, electrical and software interfaces). * Background in start-up or scale-up environments where rapid prototyping, iterative testing and pragmatic engineering decisions are typical.

STARK

ABOUT US STARK is a new kind of defence technology company revolutionising 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. ABOUT THE TEAM Minerva is STARK's command and control software — the brain that connects operators to autonomous systems across multiple domains in real time. The Minerva team is a small, senior software group based across the UK, Germany, Greece & Ukraine working directly with our systems and hardware teams to build mission-critical C2 capabilities deployed in active operational environments. We move fast, ship real software, and operate under constraints most engineers never encounter — low-bandwidth networks, air-gapped devices, and high-stakes decision loops. There is no room for abstraction for its own sake. Everything we build ends up in the hands of real operators in the field. YOUR MISSION This role demands more than standard simulation engineering. Working in defence technology means operating close to the realities of modern conflict and building simulation environments that must reliably support development, validation, and mission preparation in demanding conditions. As a Simulation Engineer, you will design, develop, and maintain high-fidelity Software-in-the-Loop (SiL) and Hardware-in-the-Loop (HiL) test rigs that help validate our autonomous marine vessels (USVs) and unmanned platforms before real-world sea trials. In addition, you will support our Mission Simulation team to incorporate Maritime environments into tactical mission training environments. RESPONSIBILITIES * HiL/SiL Test Rig Development: Architect, build, and maintain high-quality Software-in-the-Loop (SiL) and Hardware-in-the-Loop (HiL) test setups for validating embedded marine autopilots, autonomy software, and robotic platforms. * Physics & Vessel Modeling: Develop and integrate physics-based models for vehicle/vessel dynamics (hydrodynamics, wave forces, thruster/propulsion mechanics, and wind effects) and sensor physics (GPS, IMU, LiDAR, Sonar, Radar, Cameras). * Autonomy Stack Integration: Connect and coordinate simulators with ROS2-based autonomy stacks, MAVLink/MAVSDK middlewares, and edge software interfaces. * Synthetic Scenarios: Create realistic virtual environments simulating GPS-denied navigation, degraded weather, and signal jamming to stress-test control algorithms. * Verification & Analysis: Conduct debugging, verification, and performance analysis between simulators and live hardware interfaces, correlating simulation fidelity with actual sea-trial logs. * Documentation: Produce structured technical documentation, design drawings, test plans, and HIL wiring/schematic reports. * Mission Simulation Support: Support in scripting realistic training scenarios and mission simulations QUALIFICATIONS * Experience modeling marine vessel physics (propulsion, hydrodynamics, hull drag). * Strong programming proficiency in C/C++ and Python. * Strong experience building dynamic models in Simulink or equivalent * Solid understanding of fluid dynamics, physics, classical mechanics, rigid-body dynamics, control theory, or system dynamics. * Hands-on experience building and maintaining HIL test benches (cabling, signal conditioning, target computer setup, and instrumentation). * Experience configuring, customizing, and running Software-in-Loop and Hardware-in-Loop testing, preferably with PX4 flight/vehicle stacks. * Experience integrating simulation frameworks with ROS2-based middleware. * Strong debugging, validation, and analytical problem-solving skills. * Comfortable working in Linux-based software development environments.. STARK Defence UK has achieved the ERS - The Defence Employer Recognition Bronze award  2026 Talent Contact: Sally Grütte-Pad, Interim Lead TA Partner, via talent@stark-defence.com NICE TO HAVE * A university degree in Control Systems, Robotics, Aerospace Engineering, Physics, or Computer Science. * Experience with Virtual Battlespace 4 (VBS4), Unreal Engine or similar defense simulation suites. * Experience with NVIDIA Omniverse, Isaac Sim, Isaac Lab, or Gazebo. * Experience modeling electro-optical (EO), infrared (IR), IMU, GNSS, barometer, LiDAR, radar, or camera sensors.