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Senior Hardware Engineer
Aircards Studio
- Haltwhistle, England, United Kingdom
- Haltwhistle, England, United Kingdom
Über
Hardware (Invisionary & Studio)
Location:
Primarily Haltwhistle workshop, some limited requirement for Newcastle HQ office
Reporting Line:
Reports to Head of Product
Timeline:
Immediate start
Employment Type:
Full-time, in-person required
Relocation support available for candidates not currently based in Newcastle/North East UK.
Role Overview The Senior Hardware Engineer is responsible for the end‑to‑end design, engineering, fabrication, testing, and deployment of all physical hardware systems across Invisionary’s interactive display platform and Aircards Studio’s immersive installations.
This is a hands‑on leadership role combining deep technical expertise with operational ownership. The role sits at the intersection of digital fabrication, interactive technology, live environments, and scalable manufacturing.
You will lead the physical realization of complex interactive systems—from single prototype units to small production runs—ensuring they are robust, safe, serviceable, and ready for real‑world deployment in retail, events, and public environments.
Core Responsibilities – Hardware Engineering & R&D
Own the hardware architecture of Invisionary interactive displays and physical installations from concept through production.
Lead mechanical, electrical, and systems engineering decisions, ensuring designs are robust, scalable, and serviceable.
Drive R&D and rapid prototyping, using CNC, 3D printing, and mixed‑material fabrication to iterate quickly while maintaining engineering discipline.
Design and develop individual hardware components and subsystems that integrate into larger, production‑ready systems.
Produce clear hardware requirements documents, specifications, and interface definitions, covering functional, environmental, safety, and operational constraints.
Specify, test, and validate hardware components including: Displays, touchscreens, projectors, and LED panels
Cameras, sensors, IoT devices, and embedded systems
Audio systems, speakers, and amplifiers
Lighting systems (LED strips, architectural lighting, DMX where applicable)
Define test plans, acceptance criteria, and QA processes, including functional, stress, thermal, and deployment testing.
Apply Six Sigma and continuous improvement principles to reduce defects, improve reliability, and standardize manufacturing outcomes.
Implement agile manufacturing and Just‑In‑Time (JIT) approaches where appropriate to balance speed, flexibility, cost, and inventory risk.
Ensure alignment with relevant ISO quality and safety standards (e.g. ISO 9001–aligned processes), embedding quality, traceability, and compliance into hardware development.
Conduct and oversee hands‑on testing, iteration, and validation in workshop and field environments.
Apply scenario planning and failure‑mode thinking to anticipate real‑world usage, misuse, transport, and environmental stresses.
Ensure all designs meet performance, thermal, safety, compliance, DFM/DFA, and long‑term serviceability requirements.
Manufacturing & Fabrication
Lead in‑house fabrication workflows across metal, wood, plastics, and composites.
Hands‑on experience with: CNC routing and milling
Metalworking (aluminium, steel)
Welding and woodworking
3D printing
Large‑format printing and finishing
Decide when to fabricate internally vs outsource, and manage external suppliers accordingly.
Establish repeatable manufacturing processes suitable for low‑to‑medium volume production.
Electrical, Audio & Lighting Systems
Design and oversee: Power distribution and electrical layouts
Integrated lighting systems
Audio system design and tuning
Work closely with electricians and specialists to ensure safe, compliant installations.
Integrate sound, lighting, and visual systems into cohesive interactive environments.
QA, Testing & Safety
Own hardware QA processes, including: Functional testing
Stress and longevity testing
Environmental and thermal testing
Ensure compliance with relevant safety standards and certifications.
Define documentation and sign‑off procedures before deployment.
Implement fault‑finding and root‑cause analysis processes for deployed units.
Operations, Logistics & Supply Chain
Manage procurement, inventory, and supply chain logistics across all hardware components.
Oversee: BOM creation and cost optimization
Inventory tracking and stock management
Shipping, crating, and transport logistics for large installations
Work closely with production and project teams to align timelines and availability.
Leadership & Team Management
Build, manage, and mentor a multidisciplinary team including: Mechanical / CAD engineers
QA testing engineers
Hardware contractors
Educate other team members on engineering best practices and methodologies.
Own workshop operations, tooling, safety processes, and scheduling.
Act as the senior escalation point for all physical system issues.
Key Projects You Will Lead
Invisionary Interactive Display Platform
Hardware engineering, manufacturing, QA, and scaling of smart display units.
Continuous improvement of reliability, modularity, and serviceability.
One‑off and short‑run immersive installations for live events, retail, and experiential projects.
End‑to‑end responsibility from fabrication to on‑site installation and teardown.
Required Experience & Skills – Technical Experience
10‑15+ years experience
in digital fabrication, manufacturing, and physical systems engineering.
Proven experience with: CNC fabrication
Metalworking and mixed‑material builds
Building and maintaining computers (PCs, GPUs, embedded systems)
Electrical systems and low‑voltage wiring
Displays, touchscreens, projectors, and LED panels
Audio systems and sound design
Lighting systems for installations and live environments
IoT, robotics, or sensor integration
Hardware QA and testing methodologies
Comfortable working across mechanical, electrical, and software‑adjacent domains.
Operational & Leadership Skills
Strong experience managing workshops and technical teams.
Excellent organizational skills across logistics, inventory, and suppliers.
Highly proactive, solution‑driven, and comfortable owning ambiguity.
Able to balance hands‑on work with strategic planning.
Industry & Environment Experience (Highly Valued)
Live events, exhibitions, retail environments, or public installations.
Interactive or immersive technology projects.
Working with large, heavy, or safety‑critical physical systems.
Experience scaling from prototype to production.
Personal Attributes
Genuinely excited by interactive, immersive, and physical technology.
Comfortable getting hands dirty while setting direction.
Strong attention to detail without losing sight of the bigger picture.
Calm and decisive under time pressure, particularly during installs or live deployments.
Working Pattern
Predominantly in the Haltwhistle workshop
Some limited requirement to work from Newcastle HQ office between 1‑4 times a month
In‑person presence is required due to the hands‑on nature of the role.
£42,077.57 - £55,584.23 a year - Full‑time
Job Details Seniority level:
Mid‑Senior level
Employment type:
Full‑time
Job function:
Engineering and Information Technology
Industries:
Advertising Services
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Sprachkenntnisse
- English
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