Steven McCarthy

CEO

Burntwood, England, United Kingdom20 yrs 2 mos experience
Most Likely To SwitchHighly Stable

Key Highlights

  • Two decades of aerospace engineering experience.
  • Expert in Additive Manufacturing and 3D printing technologies.
  • Proven track record in leading multimillion-dollar aerospace projects.
Stackforce AI infers this person is a highly skilled Aerospace and Additive Manufacturing Engineer with extensive project management experience.

Contact

LinkedIn

Skills

Core Skills

Additive Manufacture

Other Skills

3D Printing3D PrototypingABSAS9100ActuatorsAdditive AnalysisAdditive EngineeringAdditive ManufacturingAerospaceAerospace EngineeringAircraftAviationAvionicsCADCATIA

About

Aerospace and Motorsport Engineering Professional. Two decades of learning, leading, changing, challenging, solving, empowering, inspiring, and still learning and loving doing it... Proven technical leadership and Programme Management skills delivering multimillion dollar programmes driving multifunction, international teams from concept to disposal. Aerospace Systems Design and Integration specialist. Primary specialisation in Mechanical High Lift Actuation Systems (Secondary Flight Controls), Civil Aircraft. Skills range from concept design of components and units through to full system integration at aircraft level including safety and maintainability. From scratch to production handover, including test and development experience. In-depth knowledge in the field of Additive Manufacturer from the machines, the materials, the technologies, the softwares, DFAM, best practices, process control, build success, and development of a full QMS dedicated to AM. Good experience in gas turbine rotatives design and certification. Fluid conveyance systems and associated program management. Specialities: Polymer 3D Printing, Additive Engineering and Additive Manufacture. Design for AM. Mechanical, Medical, Dental. Prototyping. Functional end use parts. Model making. Tooling. Inspection fixtures. Test Rig fixtures. Housings, Covers, Brackets, Casings. Bushes, Caps, Vessels. Electronic equipment housings. Motorsport components. Aerospace, Automotive, Industrial. In-depth understanding and analysis of safety critical aircraft high lift system design and integration. Development of design schemes from scratch - assemblies, piece parts, systems. Customer interface/liaison expert. 3D CAD user - Catia, SolidWorks - full design, design interrogation, detailed drawings. Project Technical Lead.

Experience

Freelance

Professional aerospace engineer

Jun 2025 – Present · 9 mos · Lichfield, England, United Kingdom · Hybrid

Mackart additive

3 roles

Senior Engineer

Sep 2016 – Present · 9 yrs 6 mos

Owner and Director

Sep 2016 – Aug 2025 · 8 yrs 11 mos

  • Whole Solution Engineering for Additive Manufacture
  • A true engineering firm with a full understanding of polymer Additive Manufacture. From concept to part, in support of your product development. SLA, FDM, FFF and CFF.
  • Reduce time to market with high quality iterative prototypes from conceptual assessments to functional parts.
  • A large range of engineering grade materials including Ultem, ABS, ASA, PP, HIPS, Nylon 6 and Composite Nylon 6CF with continuous fibres of carbon, kevlar(tm) or glass. Metal printing now available using the latest deposition sintered technology in 17-4PH.
  • The philosophy and goal is to be 'the' added value additive design and make resource to work as part of your team.
  • Low volume manufacture in plastics without the impact of minimum order quantities, one offs to long term production.
  • Taking a foundation of two decades in mechanical component, assembly, systems and manufacturing engineering along with high level technical programme leadership experience, ensures a robust approach and successful outcome.
  • Additive Manufacture | 3D Printing | CFF | FDM | FFF | SLA | Solidworks.
Additive Manufacture

Engineering Leader

Sep 2016 – Aug 2025 · 8 yrs 11 mos

Utc aerospace systems

Engineering IPT Systems Lead

Aug 2013 – Sep 2016 · 3 yrs 1 mo · Wolverhampton, United Kingdom · On-site

  • Engineering Systems IPT Lead managing the New Product Introduction of the Irkut MC-21 High Lift Actuation System (hydro-mechanical-control). Leading a local team circa 50 strong with remote UTC business suppliers located internationally. Engineering Management, full project technical responsibility and airworthiness signatory. Customer-Internal-Supplier focal interface. Responsible for planning, resource, financial control, program delivery.

United technologies

Technical Lead Engineer

Jun 2012 – Aug 2013 · 1 yr 2 mos · Wolverhampton, United Kingdom · On-site

Goodrich actuation systems

Technical Lead Engineer

May 2011 – Jun 2012 · 1 yr 1 mo · Wolverhampton, England, United Kingdom · On-site

Eaton - fluid conveyance systems

Contract via SME - Engineering Programme Manager

Sep 2008 – Oct 2009 · 1 yr 1 mo · Redditch, England, United Kingdom · On-site

  • Introducing a correctly programme managed process to new projects. Coordinating with customers and internally to Eaton. Driving to achieve programme deliverables. Also entailed a significant exposure to product and some product design consultation. Excellent appreciation for fluid conveyance gained.

Liebherr aerospace and transportation

Contract via SME - Systems Design Integration Lead

Jan 2006 – Apr 2012 · 6 yrs 3 mos · Lindenberg, Rhineland-Palatinate, Germany · Hybrid

  • Customers and projects include:
  • Liebherr Aerospace - Lindenberg GmbH; Consulted to in the field of mechanical High Lift Actuation Systems. Working as a technical lead and customer liaison for Bombardier and Learjet programs.
  • Ashot Ashkelon; Consulted to in the field of mechanical transmission systems design for aircraft actuation system applications.
  • Several non aerospace customers included in the portfolio; Secal Laser, Ecotronic, Airgonomics.

Rolls-royce

Contract through SME - Systems Design Engineer.

Jan 2006 – Sep 2008 · 2 yrs 8 mos · Bristol, England, United Kingdom · On-site

  • Acting in the role of Systems Design Engineer in the Helicopters and Small Gas Turbines business of Rolls Royce. Activities included Technical Life reviews of ageing engines. Certification document writing of new engines. High temperature, high strain rate materials investigations (by Hopkinson’s Bar method).

Moog aircraft

Lead Mechanical Design Engineer

Sep 2000 – Dec 2005 · 5 yrs 3 mos · Wolverhampton, United Kingdom · On-site

  • (Smiths Aerospace during my time employed) Joined as a Design Engineer, moved quickly into Senior Design Engineer and onto Lead Design Engineer for the Airbus Team. My highlight and primary project was the design and development of Airbus A380's mechanical high lift actuation system. I led up to 20 engineers at any one time, communicated and worked directly with Airbus to derive the system as a whole.

Education

University of Staffordshire

Bachelor of Engineering - BE — Mechanical Engineering

Sep 1994 – Jul 1999

University of Staffordshire

BEng (Hons) 2:1 — Mechanical Engineering

Jan 1995 – Jan 1999