{"id":3702111,"url":"https://alion.io/job/ultra-pcs-principal-mechanical-design-engineer","title":"Principal Mechanical Design Engineer","company":{"id":1959480,"name":"Ultra PCS","domain":"ultra-pcs.com","url":"https://alion.io/company/ultra-pcs","size_band":"201-500","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Workday","truth_index":{"grade":"A","score":92,"open_postings":3,"ghost_share":0,"stale_share":0.333,"repost_share":0,"time_to_fill_p50_days":47,"computed_at":"2026-11-06T05:58:05Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"lead","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Maidenhead, United Kingdom"],"countries":["GB"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":null,"experience_years_min":null,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"GD&T","optional":false},{"name":"Microsoft Office","optional":false},{"name":"TEMPEST","optional":false},{"name":"Verification & Validation","optional":true}],"status":"live","first_seen_at":"2026-11-03T19:51:45Z","employer_posted_date":"2026-11-03","last_verified_at":"2026-11-06T06:39:20Z","board_verified":true,"closed_at":null,"days_open":2,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":2},"description":"Company: Ultra Intelligence & Communications\nCyber (UK) BusinessPowering Decision\nJoin 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.\nCyber Business\nOur 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.\nJob Description\nAs 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\nDefine and manage mechanical design requirements, ensuring validation and verification.\nResponsible for developing, documenting and delivering robust mechanical solutions for complex systems using the 3D CAD system and the company engineering toolsets.\nLead mechanical integration, verification, and acceptance testing, collecting and presenting evidence as required.\nCreate and peer review technical artefacts, including mechanical design documentation, design data packs, analysis reports, plans and procedures in accordance with our product development framework.\nDefine, analyse and document predicted mechanical functional behaviours and performance.\nOptimize the design of parts based on various manufacturing technologies: machined from solid, injection moulding, extrusion, sheet metal and casting.\nPerform tolerance analysis of close tolerance parts and complex assemblies.\nProduce mechanical designs for complex systems that meet defence standards MIL-STD and DEF-STAN, EMC and TEMPEST requirements and harsh environmental conditions. \nCreate and review high-quality drawings to BS8888 standard to guarantee design precision.\nSelect optimum engineering materials and finishes to suit cost and performance.\nIdentify and integrate Commercial Off-The-Shelf (COTS) mechanical hardware, ensuring compliance with design specifications, rationalising cost, lead time and long-term component availability.\nDesign production jigs and fixtures in conjunction with production engineers.\n3D Print and scan components; and produce rapid prototypes.\nHold and contribute to peer design reviews ensuring adherence to design processes.\nDynamically prioritize daily tasks and cross-functional workstreams, ensuring tight project deadlines are consistently met under high-pressure constraints.\nConduct rigorous design reviews of mechanical drawings, ensuring precise application of Geometric Dimensioning and Tolerancing (GD&T) to guarantee clarity and component functionality.\nResponsible for mechanical test solution and development of test procedures to support the verification of the product.\nPrepare and present mechanical technical solutions to stakeholders.\nFollow configuration control and security procedures diligently.\nLiaise with the production and supply chain teams to ensure a seamless transition to manufacture.\nInterface with the electronic hardware and PCB design teams to understand their constraints and convey the mechanical solutions.\nChampion a culture of continuous improvement, regularly reviewing workflows and implementing data-driven changes to optimize productivity.\nPartner with Project Management to optimize schedules, mitigate development risks, and maintain strict alignment with budget and timeline constraints.\nCollaborate on commercial bids and proposals with the Sales team by developing robust execution plans, scoping technical requirements, and generating reliable cost and labour estimates.\nEssential Skills, Qualification and Experience\nDegree in Mechanical Engineering or closely related discipline.\nProfound 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.\nSeasoned experience in hands-on design of complex and rugged electronic enclosures for the defence industry.\nExhibit strong analytical and problem-solving skills.\nIn-depth knowledge of military standards applicable to environmental requirements and testing.\nExtensive experience of 3D CAD modelling and drafting. Creo CAD version 7 or later is preferable.\nDeep technical expertise of undertaking stress and thermal analysis using hand calculations, FEA and CFD.\nLong term experience of using PLM systems, preferably Windchill. \nProven track record managing BOMs on PLM systems and interfacing with ERP systems.\nWell-versed in using electronic workflow and document change management system.\nProven ability to multi-task, prioritise workload, and work under pressure to deliver on multiple projects simultaneously.\nMeticulous in drafting and reviewing complex engineering drawings to guarantee design precision.\nProficient in authoring clear, concise technical reports and comprehensive engineering documentation.\nProven ability to perform tolerance analysis complex assemblies and deploy GD&T.\nSkilled in integrating EMC and TEMPEST shielding principles into mechanical architectures.\nA strong grasp of designing for additive manufacturing (DfAM), with a deep understanding of 3D printing, scanning workflows, and the technical constraints of various rapid prototyping technologies.\nAdvanced proficiency in Microsoft Office tools for data modelling, report generation, and stakeholder presentations. \nModel good interpersonal skills and teamwork; and the ability to communicate effectively at all levels. \nDemonstrate a helpful 'can do' attitude.\nDesired Skills, Qualification and Experience\nExperience of Mechanical Integration, Verification and Validation activities.\nSkilled in writing mechanical requirements based on systems requirements using proprietary software.\nKnowledge of hazardous materials, ROHS and REACH restrictions.\nPossess UK driving license.\nSecurity Clearance\nCandidates must be willing and able to obtain, and maintain, DV security clearance \nNotice\nDue to the nature of the programs we deliver for our customers, candidates may need to obtain the relevant security clearance or handle export-controlled material as defined by the role's requirements. Applicants must be able to obtain and maintain the appropriate level of security clearance for the role. Due to the nature of our work, you must be a British Citizen who has been resident in the UK for the past 5 years in order to apply for SC clearance and 10 years for DV. For more information, please visit the UKSV website.\nOur Benefits\nEvery employee is critical to our success, and as such, we offer a range of flexible employee benefits, including:\nParticipation in an Annual Bonus Scheme\n\nPrivate Medical Cover\n\n25 days’ holiday (plus Bank Holidays) with the option to buy an extra 5 days\n\nPension Contribution\n\n4 x Life Assurance Cover\n\nFlexible working hours with opportunity for a 1pm finish on a Friday\n\nFlexible benefits including cycle to work scheme, will writing and more\n\nSecurity Clearance Allowance - where relevant and subject to you holding the required security clearance\n\nDiversity, Equity & Inclusion Statement\nAt Ultra I&C, we are an equal opportunity employer and value diversity and inclusivity. Underpinned by our values, behaviours, and policies, we want you to feel empowered to be the best version of yourself. We also believe that people from different backgrounds and cultures will increase our diversity of thinking, ensuring we successfully deliver to our customers. We, therefore, do not discriminate based on race, religion, colour, national origin, gender, sexual orientation, age, marital status, veteran status, or disability status. We also support requests for flexible working arrangements wherever possible. 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