Principal Mechanical Design Engineer in Maidenhead

Company: Ultra Intelligence & Communications

Cyber (UK) Business

Powering Decision

Join the team redefining defense technology. From engineering systems that save lives to leading programs that change the battlefield-find your place in the future of defense.

Cyber Business

Our Cyber business unit is at the forefront of pioneering advanced cryptographic and key management solutions, facilitating the confidential exchange of vital information for customers operating at both tactical and strategic echelons. Join our team and participate in the innovation that ensures the highest security and trust worldwide.

Job Description

As a Principal Mechanical Engineer, you will provide technical expertise across the design, development, testing and qualification of mechanical assemblies for advanced security critical products. You will lead mechanical engineering activities from concept through to production, ensuring designs meet functional, environmental and regulatory requirements. Leveraging deep technical expertise, significant previous experience and analytical problem-solving; you will make critical engineering decisions to deliver high-quality design outputs. In this role, you will also serve as a technical anchor, mentoring junior engineers and continuously driving engineering excellence across the team.

Key Responsibilities

• Define and manage mechanical design requirements, ensuring validation and verification.
• Responsible for developing, documenting and delivering robust mechanical solutions for complex systems using the 3D CAD system and the company engineering toolsets.
• Lead mechanical integration, verification, and acceptance testing, collecting and presenting evidence as required.
• Create and peer review technical artefacts, including mechanical design documentation, design data packs, analysis reports, plans and procedures in accordance with our product development framework.
• Define, analyse and document predicted mechanical functional behaviours and performance.
• Optimize the design of parts based on various manufacturing technologies: machined from solid, injection moulding, extrusion, sheet metal and casting.
• Perform tolerance analysis of close tolerance parts and complex assemblies.
• Produce mechanical designs for complex systems that meet defence standards MIL-STD and DEF-STAN, EMC and TEMPEST requirements and harsh environmental conditions.
• Create and review high-quality drawings to BS8888 standard to guarantee design precision.
• Select optimum engineering materials and finishes to suit cost and performance.
• Identify and integrate Commercial Off-The-Shelf (COTS) mechanical hardware, ensuring compliance with design specifications, rationalising cost, lead time and long‑term component availability.
• Design production jigs and fixtures in conjunction with production engineers.
• 3D Print and scan components; and produce rapid prototypes.
• Hold and contribute to peer design reviews ensuring adherence to design processes.
• Dynamically prioritize daily tasks and cross‑functional workstreams, ensuring tight project deadlines are consistently met under high‑pressure constraints.
• Conduct rigorous design reviews of mechanical drawings, ensuring precise application of Geometric Dimensioning and Tolerancing (GD&T) to guarantee clarity and component functionality.
• Responsible for mechanical test solution and development of test procedures to support the verification of the product.
• Prepare and present mechanical technical solutions to stakeholders.
• Follow configuration control and security procedures diligently.
• Liaise with the production and supply chain teams to ensure a seamless transition to manufacture.
• Interface with the electronic hardware and PCB design teams to understand their constraints and convey the mechanical solutions.
• Champion a culture of continuous improvement, regularly reviewing workflows and implementing data‑driven changes to optimize productivity.
• Partner with Project Management to optimize schedules, mitigate development risks, and maintain strict alignment with budget and timeline constraints.
• Collaborate on commercial bids and proposals with the Sales team by developing robust execution plans, scoping technical requirements, and generating reliable cost and labour estimates.

Essential Skills, Qualification and Experience

• Degree in Mechanical Engineering or closely related discipline.
• Profound understanding of key mechanical engineering principles e.g. materials science and selection, engineering mechanics, stress analysis, vibration analysis, thermodynamics, heat transfer, assembly techniques and manufacturing processes.
• Seasoned experience in hands‑on design of complex and rugged electronic enclosures for the defence industry.
• Exhibit strong analytical and problem‑solving skills.
• In‑depth knowledge of military standards applicable to environmental requirements and testing.
• Extensive experience of 3D CAD modelling and drafting. Creo CAD version 7 or later is preferable.
• Deep technical ex