Senior Mechatronics Engineer in Devon, Exeter

Location: Exeter, Devon (on-site)

Type: Full-time, Permanent

Salary: Competitive + Benefits

Rapid Fusion designs and manufactures advanced robotic large-format additive manufacturing (LFAM) systems used in defence, aerospace, marine, and commercial sectors. Our platforms span both industrial robotic arms and large-format gantry systems, all built around high-throughput pellet extrusion and capable of printing large structural components that can't be made any other way. We need a Senior Mechatronics Engineer with a strong additive manufacturing background to take full technical ownership across hardware, process, and user-facing software — leading a current programme to production readiness and then driving engineering across our broader platform portfolio.

You will manage a current mechatronics engineer and lead UI development alongside the wider software team.

• Manage a current mechatronics engineer: direct their work, unblock them, and be accountable for their output
• Own end-to-end systems integration on a robotic large-format additive manufacturing platform, from current development state to production readiness
• Develop and validate process parameters — temperatures, pressures, speeds, layer strategy — to achieve consistent, repeatable print quality
• Lead UI development for operator-facing interfaces — working with the software team to define requirements, review designs, and ensure the HMI reflects real operator needs
• Define and execute acceptance testing and commissioning procedures, including print quality benchmarks
• Manage technical interfaces with suppliers and sub-contractors

Ongoing Engineering

• Lead mechatronics and process engineering on future LFAM platform development
• Build and maintain material characterisation capability — working with engineering polymers, composites, and high-temperature materials
• Set hardware and process engineering standards across the platform portfolio
• Support compliance work including CE/UKCA declarations, PSSR, and machinery risk assessments
• Hands-on experience with large-format or industrial additive manufacturing systems — pellet extrusion, FGF, WAAM, or similar
• Strong process engineering background: understanding of how hardware parameters drive print quality, material behaviour, and structural performance
• Systems integration experience across mechanical, electrical, and control domains — comfortable owning all three
• Experience leading UI or HMI development for industrial or manufacturing systems — you understand what operators need and can translate that into a usable interface
• Experience developing and validating process parameters for engineering-grade or high-performance materials
• Experience programming and configuring motion controllers for CNC or gantry-based systems — setting up axes, tuning motion profiles, and integrating peripheral hardware
• Ability to own technical documentation end-to-end: schematics, assembly drawings, FMEA, test plans, commissioning records
• Familiarity with KUKA KRC4/KRC5 and KRL programming, or Siemens CNC/motion control (S7, Sinumerik, or similar)
• Knowledge of engineering polymers and composites in an AM context — ABS, PA, PETG, CF/GF-filled materials
• Direct involvement in defence, aerospace, and marine programmes

Competitive salary, reviewed regularly as the company grows. Pension, 22 days holiday + bank holidays. Opportunity to grow into a Head of Engineering role as the team scales.