Mechanical Designer / Prototyping Engineer

📍 Job Overview

Job Title: Mechanical Designer / Prototyping Engineer

Company: STARK

Location: Munich, Germany

Job Type: Permanent employee

Category: Engineering / Hardware Development

Date Posted: June 03, 2026

Experience Level: 5-10 years

Remote Status: On-site

🚀 Role Summary

• This role focuses on the end-to-end mechanical design and rapid prototyping of critical components for advanced unmanned systems, directly impacting operational deployment.

• It requires a blend of digital design skills using CAD software and extensive hands-on fabrication experience in a workshop environment.

• The position involves close collaboration with cross-functional engineering teams (software, hardware, electronics) to ensure seamless integration and rapid iteration of designs for real-world applications.

• Success in this role hinges on a pragmatic, problem-solving approach, an ability to work under constraints, and a strong "maker" mentality to deliver functional prototypes quickly.

📝 Enhancement Note: While the input job title is "Mechanical Designer / Prototyping Engineer," the description strongly emphasizes hands-on fabrication and rapid iteration, aligning it with roles that bridge design and practical engineering execution. The defense sector context implies a need for robust, reliable, and potentially ruggedized designs.

📈 Primary Responsibilities

• Design mechanical components, assemblies, fixtures, enclosures, mounts, brackets, and integration parts for unmanned systems, ground systems, and associated hardware.

• Engage in rapid iteration cycles, adapting designs based on feedback from engineering, testing, production, and operational use to accelerate development timelines.

• Develop designs that are simple, robust, and optimized for rapid manufacturing, both internally and with external partners, adhering to Design for Manufacturing and Assembly (DFMA) principles.

• Fabricate, modify, assemble, and repair prototypes using a range of tools including 3D printers, hand tools, power tools, soldering equipment, and basic workshop machinery.

• Assemble mechanical and electromechanical prototypes, integrating them with electronic components, cables, sensors, antennas, and power systems.

• Conduct testing and validation of prototypes in workshop, lab, and field settings to identify mechanical weaknesses or integration issues and implement practical solutions.

• Collaborate closely with engineering, hardware, electronics, software, production, and field testing teams to ensure mechanical designs meet all functional, operational, and integration requirements.

• Create and maintain clear technical documentation, including CAD files, drawings, assembly instructions, Bill of Materials (BOMs), and detailed notes from testing and iteration processes.

📝 Enhancement Note: The responsibilities highlight a "hands-on" approach, emphasizing fabrication and integration beyond pure CAD work. The mention of "real-world constraints," "low-bandwidth networks," and "air-gapped devices" from the team description suggests a focus on practical, robust design solutions suitable for challenging operational environments.

🎓 Skills & Qualifications

Education:

• Degree or vocational background in Mechanical Engineering, Mechatronics, Product Development, Industrial Design Engineering, Manufacturing Engineering, or a closely related technical field.

Experience:

Required Skills:

• Strong proficiency in 3D CAD software (e.g., SolidWorks, Autodesk Fusion 360, Inventor, CATIA, Siemens NX).

• Proven hands-on experience in building, modifying, assembling, and testing physical prototypes.

• Deep practical understanding of 3D printing technologies (FDM, and ideally SLA/SLS), including material selection, printer operation, calibration, and design-for-print principles.

• Confident and safe use of common workshop tools, hand tools, power tools, soldering equipment, basic machinery, and manual assembly techniques.

• Solid understanding of design principles including tolerances, materials, fasteners, mechanical interfaces, load paths, vibration and thermal loads, environmental exposure, manufacturability, serviceability, and assembly efficiency.

• Highly proactive, self-reliant, and comfortable working independently in a fast-paced, experimental environment with potentially incomplete information.

• Excellent communication and collaboration skills for effective integration with cross-functional teams and clear documentation of work.

Preferred Skills:

• Experience in defense, aerospace, UAVs (Unmanned Aerial Vehicles), robotics, automotive, or motorsport industries.

• Experience designing and building components for drones, ground control stations, sensor payloads, field equipment, ruggedized hardware, or mobile systems.

• Familiarity with composite materials, foam, plastics, aluminum, sheet metal, or lightweight structural components.

• Basic knowledge of electronics integration, cable routing, connector mounting, power components, sensors, antennas, or embedded hardware.

• Experience with CNC machining, laser cutting, waterjet cutting, vacuum forming, casting, or other rapid manufacturing methods.

• Experience creating detailed technical drawings, assembly instructions, Bills of Materials (BOMs), and manufacturing documentation.

• Strong German language skills would be advantageous for local collaboration.

📝 Enhancement Note: The emphasis on "exceptional practical experience" compensating for formal education is a key indicator for roles valuing hands-on expertise. The inclusion of specific CAD packages and 3D printing technologies helps filter for candidates with directly applicable skills. The security clearance is a critical, non-negotiable requirement.

📊 Process & Systems Portfolio Requirements

Portfolio Essentials:

• Demonstrate a portfolio showcasing a range of mechanical designs and physical prototypes, highlighting the transition from concept to functional hardware.

• Include examples of rapid iteration and how design decisions evolved based on testing or feedback, showing a process of improvement.

• Present case studies of components designed for specific functional requirements, including considerations for manufacturability and assembly.

Process Documentation:

• Provide examples of technical documentation created for designs, such as CAD models, 2D drawings, assembly instructions, and Bill of Materials (BOMs).

• Illustrate the process of testing and validation, including any data collected or modifications made based on results.

• Document the approach to problem-solving in design and fabrication, detailing challenges encountered and solutions implemented.

📝 Enhancement Note: For a hands-on prototyping role, a portfolio is crucial. It should not just contain CAD renders but evidence of physical creation, successful integration, and problem-solving. The ability to document the process and outcomes is as important as the design itself.

💵 Compensation & Benefits

Salary Range:

Benefits:

• Competitive salary package commensurate with experience and skills.

• Opportunities to work on cutting-edge defense technology and contribute to critical national security systems.

• Dynamic and fast-paced work environment with a focus on innovation and rapid deployment.

• Collaborative team culture with direct impact on product development and operational success.

• Potential for professional development and skill enhancement in specialized engineering fields.

Working Hours:

• Standard 40-hour work week, common for permanent roles in Germany. The role may require flexibility and occasional overtime to meet critical project deadlines and rapid iteration cycles, especially during testing and integration phases.

📝 Enhancement Note: Salary estimates are based on average compensation data for experienced mechanical engineers in Munich, Germany, adjusted for the specialized defense sector. Benefits are inferred from the company's mission and the nature of advanced technology development.

🎯 Team & Company Context

🏢 Company Culture

Industry: Defense Technology, Autonomous Systems, Aerospace, Robotics. STARK is positioned at the forefront of modern defense, developing software-defined, mass-scalable, and cost-effective unmanned systems to provide a decisive operational edge.

Company Size: The provided data does not specify company size, but the description of the Minerva team as "small, senior software group" suggests STARK is likely a growing, agile organization, potentially a startup or scale-up in the defense tech sector. This implies a lean structure, rapid decision-making, and a high degree of individual responsibility.

Founded: The founding date is not provided, but the company's mission to "deter aggression and defend Europe—today" suggests a relatively recent establishment focused on addressing current geopolitical needs.

Team Structure:

• The Minerva team is described as a "small, senior software group," indicating a highly experienced and specialized unit.

• This team works directly with "systems and hardware teams," suggesting close integration between software, mechanical, and electrical engineering disciplines.

Methodology:

• Emphasis on "moving fast, shipping real software, and operating under constraints" points to agile development methodologies adapted for mission-critical environments.

• The team operates with "low-bandwidth networks, air-gapped devices, high-stakes decision loops," requiring pragmatic, efficient, and robust engineering solutions rather than abstract theoretical approaches.

• A strong focus on "real operators in the field" guides development, ensuring practical applicability and reliability.

Company Website: starkfuture.com (derived from domain_derived)

📝 Enhancement Note: The company's focus on "deployable, high-performance systems—not future promises" and its mission to "deter aggression and defend Europe—today" indicates a practical, results-oriented culture. The mention of "mission-critical C2 capabilities deployed in active operational environments" underscores the high stakes and need for reliability.

📈 Career & Growth Analysis

Operations Career Level: This role is positioned as a key contributor within the engineering team, requiring significant practical experience (5+ years). It's not an entry-level position but rather for seasoned engineers who can operate with a high degree of autonomy. The role involves both design and hands-on execution, making it ideal for engineers who enjoy seeing their designs come to life and are comfortable working directly with hardware.

Reporting Structure: While not explicitly stated, given the description of the "Minerva team" as a "small, senior software group" working closely with hardware teams, this Mechanical Designer / Prototyping Engineer would likely report to a Lead Mechanical Engineer, Engineering Manager, or Head of Hardware Development. Collaboration will be extensive across various engineering disciplines.

Operations Impact: The mechanical designs and prototypes developed in this role are critical for the functionality and deployment of STARK's unmanned systems. The engineer's work directly influences the performance, reliability, and manufacturability of these systems, which are intended for active operational use in defense scenarios. Therefore, the impact is direct and significant, contributing to the company's mission to provide a decisive technological edge.

Growth Opportunities:

• Specialization: Deepen expertise in specific areas like advanced materials, ruggedized design, or integration of complex electromechanical systems within the defense domain.

• Leadership: Potentially transition into a Senior Mechanical Engineer role, leading design efforts for specific subsystems or taking on mentorship responsibilities for junior engineers.

• Broader System Understanding: Develop a comprehensive understanding of how mechanical components integrate with software and electronics in complex autonomous systems, potentially leading to roles in systems engineering or hardware architecture.

• Process Improvement: Drive improvements in the company's prototyping and design-for-manufacturing processes.

📝 Enhancement Note: The role offers growth beyond traditional mechanical design by emphasizing integration and hands-on prototyping in a mission-critical sector. The "maker" aspect combined with engineering rigor provides a unique career path.

🌐 Work Environment

Office Type: The description implies a blend of office and workshop environments. The "Minerva team" is based in Berlin and Munich, suggesting modern office spaces. However, the "hands-on fabrication" and "workshop machinery" requirements indicate dedicated lab or workshop facilities are integral to the role.

Office Location(s): Munich, Germany. This is a major technology and engineering hub in Europe, offering a strong ecosystem for talent and innovation.

Workspace Context:

• The environment is described as "fast-moving, experimental," and requiring work under "real-world constraints." This suggests a dynamic, potentially high-pressure setting where adaptability is key.

• Close collaboration with software, hardware, and electronics teams is expected, fostering a cross-functional and integrated workspace.

Work Schedule:

• The standard 40-hour work week is typical for a full-time position in Germany. However, the "rapid iteration" and "mission-critical" nature of the work may necessitate flexibility and occasional extended hours to meet project deadlines and operational demands.

📝 Enhancement Note: The work environment is characterized by a blend of theoretical design and practical, hands-on execution, set within a high-stakes defense technology context. This requires a candidate who thrives in a dynamic, collaborative, and resource-constrained setting.

📄 Application & Portfolio Review Process

Interview Process:

• Initial Screening: A review of your CV and portfolio to assess relevant experience, technical skills, and alignment with the role's hands-on requirements.

• Technical Interview(s): In-depth discussions focused on your mechanical design principles, CAD proficiency, prototyping experience, problem-solving approach, and understanding of materials and manufacturing processes. Expect questions about specific projects and challenges encountered.

• Portfolio Review Session: A dedicated session where you will present and walk through selected projects from your portfolio, explaining your design process, fabrication methods, integration challenges, and outcomes. This is a critical stage to demonstrate practical skills.

• Hands-on/Workshop Assessment (Potential): Depending on the candidate's experience and the interviewer's discretion, a practical assessment or a detailed discussion about workshop capabilities and safety might occur.

• Cultural Fit & Security Clearance Discussion: Interviews to assess your fit with the company's fast-paced, pragmatic culture and to discuss the requirements and process for obtaining security clearance.

Portfolio Review Tips:

• Curate Selectively: Choose 3-5 projects that best showcase your diverse skills in mechanical design, hands-on prototyping, and integration. Prioritize projects that demonstrate problem-solving and iteration.

• Show, Don't Just Tell: For each project, include high-quality photos or videos of the physical prototypes, CAD models, relevant drawings, and explanations of the fabrication process.

• Highlight Iteration: Clearly explain the design journey, including any challenges faced, changes made, and the rationale behind them. This demonstrates adaptability and learning.

• Quantify Impact: Where possible, mention the functional improvements or efficiencies gained by your designs or prototypes.

• Explain Integration: Detail how your mechanical designs interfaced with electronics, software, or other hardware components.

• Be Ready for Technical Deep Dives: Prepare to discuss material properties, manufacturing tolerances, assembly procedures, and the specific tools and techniques you used.

Challenge Preparation:

• While a formal "challenge" might not be outlined, be prepared for technical questions that simulate design problems or integration scenarios.

• Practice articulating your design process and problem-solving methodology clearly and concisely.

• Review fundamental mechanical engineering principles, especially those related to stress analysis, materials, fasteners, and common manufacturing methods.

📝 Enhancement Note: The emphasis on "hands-on fabrication" and "rapid iteration" means the portfolio review will likely be very practical, requiring candidates to demonstrate not just design capability but also their ability to build and test.

🛠 Tools & Technology Stack

Primary Tools:

• 3D CAD Software: Proficiency required in at least one major package such as SolidWorks, Autodesk Fusion 360, Inventor, CATIA, or Siemens NX. Candidates should be comfortable with part design, assembly creation, and generating technical drawings.

• 3D Printers: Hands-on experience with FDM (Fused Deposition Modeling) is essential. Experience with SLA (Stereolithography) or SLS (Selective Laser Sintering) is a strong plus. This includes understanding printer operation, calibration, maintenance, and design considerations specific to additive manufacturing.

• Workshop Machinery & Tools: Familiarity and safe operation of hand tools, power drills, basic metalworking machinery, soldering equipment, and manual assembly techniques.

• Measurement Tools: Experience using calipers, micrometers, and other precision measuring instruments for quality control and assembly.

Analytics & Reporting:

CRM & Automation:

Integration Tools:

• Experience with integrating mechanical components with electronic systems, including cable management, connector mounting, and sensor/antenna placement.

📝 Enhancement Note: The tech stack is heavily weighted towards design and fabrication tools. The emphasis on specific CAD packages and 3D printing technologies is critical. Knowledge of integration with electronics is also a key area.

👥 Team Culture & Values

Operations Values:

• Pragmatism & Practicality: A strong emphasis on building functional, reliable solutions that work in real-world, often constrained, environments. Abstract or theoretical solutions are less valued than deployable ones.

• Speed & Agility: The ability to move fast, iterate quickly, and adapt designs based on feedback is paramount. "Shipping real software and hardware" is a core tenet.

• Independence & Initiative: Engineers are expected to be proactive, self-reliant, and comfortable solving problems with incomplete information.

• Collaboration & Communication: While independence is valued, close collaboration with diverse engineering teams is essential for successful integration and development. Clear communication is key.

• Mission Focus: A deep commitment to the company's mission of enhancing defense capabilities and providing a technological edge for allies.

Collaboration Style:

• Cross-Functional Integration: Engineers work closely with software, hardware, and electronics teams, fostering a collaborative environment where mechanical designs are considered in the context of the entire system.

• Iterative Feedback Loops: Design and testing processes involve continuous feedback from various stakeholders, including other engineers, technicians, and potentially end-users, to refine prototypes rapidly.

• Knowledge Sharing: Open communication and sharing of lessons learned from prototyping and testing are encouraged to improve future designs and processes.

📝 Enhancement Note: The culture is geared towards action, results, and practical application, especially within the demanding context of defense technology. It requires individuals who are not only technically skilled but also adaptable, proactive, and mission-driven.

⚡ Challenges & Growth Opportunities

Challenges:

• Working Under Constraints: Designing and prototyping for environments with limited bandwidth, air-gapped systems, and high-stakes operational demands requires innovative and robust solutions.

• Rapid Iteration Cycles: The need to quickly design, build, test, and iterate can be demanding, requiring efficient workflows and rapid problem-solving.

• Integration Complexity: Seamlessly integrating mechanical components with sophisticated electronics, software, and sensors in unmanned systems presents significant technical challenges.

• Balancing Design and Fabrication: Effectively transitioning from digital design to hands-on physical creation, ensuring manufacturability and reliability from the outset.

Learning & Development Opportunities:

• Advanced Prototyping Techniques: Gaining hands-on experience with a variety of fabrication methods and materials relevant to advanced unmanned systems.

• Defense Sector Expertise: Developing a deep understanding of the unique requirements and operational contexts of the defense and aerospace industries.

• Cross-Disciplinary Knowledge: Expanding knowledge in electronics integration, embedded systems, and software interaction with hardware.

• Process Optimization: Contributing to and learning from the company's methods for rapid prototyping and design-for-manufacturability in a high-stakes environment.

📝 Enhancement Note: The challenges are inherent to working in a cutting-edge, high-impact sector like defense technology, offering substantial opportunities for professional growth and skill development.

💡 Interview Preparation

Strategy Questions:

• Design Process: "Walk me through a complex mechanical prototype you designed and built. What were the key requirements, your design process, the fabrication challenges, and the final outcome?" Be prepared to discuss your CAD workflow, material choices, assembly methods, and testing procedures.

• Problem-Solving: "Describe a time you encountered a significant mechanical failure or integration issue with a prototype. How did you diagnose the problem, what solution did you implement, and what did you learn?" Focus on your analytical and practical problem-solving skills.

• Design for Manufacturing: "How do you approach designing for manufacturability and assembly, especially when rapid prototyping is a priority?" Discuss your understanding of DFMA principles and how you balance speed with production feasibility.

Company & Culture Questions:

• Motivation: "Why are you interested in working in the defense technology sector, and specifically at STARK?" Connect your passion for engineering with the company's mission.

• Adaptability: "This role requires working with incomplete information and under tight deadlines. Can you give an example of when you successfully navigated such a situation?" Highlight your proactive and self-reliant nature.

• Collaboration: "Describe your experience working with software and electronics engineers. How do you ensure smooth integration between mechanical designs and other system components?" Emphasize your communication and cross-functional collaboration skills.

Portfolio Presentation Strategy:

• Structure Your Presentation: For each project, clearly state the objective, your role, the design approach, key technical challenges, the fabrication/prototyping process, and the final results/lessons learned.

• Focus on "Maker" Aspects: Emphasize the hands-on fabrication, assembly, and testing you performed. Use visuals (photos, videos) of the physical product.

• Demonstrate Problem-Solving: Clearly articulate any issues encountered during design or fabrication and how you overcame them.

• Explain Trade-offs: Discuss any design compromises made due to constraints (time, budget, materials) and your rationale.

• Be Ready for Technical Questions: Anticipate detailed questions about your CAD choices, material properties, manufacturing tolerances, and assembly techniques.

📝 Enhancement Note: The interview process will heavily scrutinize practical skills. A strong portfolio demonstrating hands-on work and the ability to articulate design and fabrication processes are crucial for success.

📌 Application Steps

To apply for this Mechanical Designer / Prototyping Engineer position:

• Submit your application through the provided link on the STARK jobs portal.

• Curate Your Portfolio: Select 3-5 of your most relevant projects that showcase your mechanical design, hands-on prototyping, and integration capabilities. Ensure you have high-quality visuals and detailed descriptions for each.

• Tailor Your CV: Highlight your 5+ years of experience in mechanical design and prototyping, emphasizing skills in CAD, 3D printing, workshop fabrication, and cross-functional collaboration. Use keywords from the job description.

• Prepare Your Presentation: Practice walking through your portfolio projects, focusing on your problem-solving approach, hands-on execution, and ability to iterate designs under constraints.

• Research STARK: Understand the company's mission, its focus on unmanned systems and defense technology, and its commitment to providing a decisive edge. This will help articulate your motivation.

⚠️ Important Notice: This enhanced job description includes AI-generated insights and operations industry-standard assumptions. All details should be verified directly with the hiring organization before making application decisions.