Senior Mechanical Design Engineer in Hereford

The company:

We are a profitable, fast-scaling defence-tech startup - operating on the extreme edge of innovation in the evolving domain of unmanned systems / drones.

Our world-class team of Engineers are delivering solutions deemed impossible by many, for some of the most complex and challenging problems in the Drones / UAS space.

With strong revenue growth, a loyal customer base, and an ambitious scaling plan, we are entering an exciting new phase of growth — and this is a rare opportunity to join at the moment it matters most.

Why this role exists:

We have multiple products in active service and demand is growing faster than our current team can deliver. Our engineers are highly capable but overloaded. We need another experienced mechanical design engineer who can take full ownership of detailed design work across our product lines and start delivering from week one.

This is a hands-on design role in a small team where the distance between your desk and the workshop is 15 metres. You will design a part, walk downstairs, watch it come off the CNC or out of the printer, assemble the prototype yourself, and iterate the same day. If you have spent your career wishing you were closer to the hardware, this is that job.

What you will do:

• Own complete mechanical assemblies from concept through production. You are responsible for the 3D model, manufacturing drawings, BOMs, and assembly instructions. When your part goes to the shop floor, the drawing is good enough that a technician can build it without asking you questions.
• Design for manufacture from the start. Select the right process for each part: CNC machining, sheet metal, injection moulding, 3D printing, composite layup. Work directly with suppliers and contract manufacturers to resolve DFM issues before committing to tooling.
• Integrate across disciplines. Package electronics, wiring, connectors, and mechanical subsystems into tight assemblies. Collaborate daily with electronics and embedded software engineers on PCB form factor, thermal paths, connector placement, and cable routing.
• Build and test. Assemble prototype hardware yourself when the timeline demands it. Support environmental and qualification testing: vibration, shock, thermal cycling, IP ingress. Analyse test failures, identify root causes, and fix your designs.
• Calculate before you commit. Use hand calculations for loads, fits, thermal expansion, and fastener selection. Use FEA when the problem demands it, not as a substitute for engineering judgment.
• Keep clean records. Maintain revision-controlled CAD data. Produce clear engineering change notes. Contribute to technical data packages for customer deliverables.

Required experience:

• Solid professional mechanical design experience in a product development environment. You must have designed parts that were manufactured and used, not just modelled or analysed.
• Strong proficiency in Siemens NX or SolidWorks. Both would be ideal. You need to be productive in 3D CAD from week one.
• Demonstrated experience designing for manufacture. You should have designed for at least two of: CNC machining, sheet metal, injection moulding, additive manufacturing, or composites. If you have never thought about how your part gets made, this role will be a struggle.
• Experience with GD&T and tolerance analysis. You know why a tolerance exists and can justify it, not just apply a default.
• Experience working alongside electronics, software, or systems engineers. Our products are multi-disciplinary. You need to be comfortable designing around other people’s hardware.
• Comfortable with hands-on work: building prototypes, basic workshop operations. If you have never touched the things you designed, expect a learning curve.

Nice to have:

• Experience designing for harsh or demanding environments: defence, aerospace, automotive, marine, industrial
• CNC programming experience (G-code, CAM software). We have in-house machining and someone who can program as well as design is extremely valuable.
• Familiarity with environmental testing standards: MIL-STD-810, DEF-STAN, IP ratings
• Experience with PLM/PDM systems (Teamcenter preferred)
• Exposure to FEA for structural and/or thermal analysis
• Experience with composite structures or lightweight structural design
• CEng, IEng, or working toward chartership through IMechE or IET

Compensation:

• Competitive annual salary
• Performance bonus
• Employee stock options
• Life and health insurance
• 35 days annual leave including public holidays