Process Engineer

About Stark

Stark builds the world’s most powerful electric motorcycles. From the VARG MX to the road-legal VARG EX & SM, our bikes have won world championships and are engineered to outperform anything with a combustion engine.

We’re based in Sant Boi, Barcelona, growing fast (77% year-on-year), and building a team that will take us even further. If you want to work on a product that people are genuinely obsessed with, this is it.

Stark will become the global market leader in premium motorcycles. Building premium motorcycles requires innovation and we need your help to make us succeed

Our mission is to lead the way towards a sustainable motorcycle industry, by reducing plastic and CO2 pollution.

This will be achieved by building sustainable products that are superior to traditional technology in terms of Performance, Emotion and Design.

The Role

As a Process Engineer, you will be responsible for the validation, performance and continuous improvement of automated and manual manufacturing processes used in battery and vehicle production.

You will act as the technical process owner for a range of production processes, including laser welding, cell insertion, fastening and manual assembly stations, ensuring that equipment and processes are safe, capable, repeatable and ready for series production.

The role has a strong hands-on manufacturing focus, covering FAT, SAT, commissioning, process validation, ramp-up and serial production support. While laser welding will be one of the key technical areas of responsibility, the position is not limited to this process and requires a broad understanding of automated manufacturing and assembly processes.

You will work closely with Production, Quality, Maintenance, R&D and equipment suppliers to ensure robust processes and achieve production, quality and cost targets.

The ideal candidate is a Process or Manufacturing Engineer with strong experience in automated production equipment and hands-on experience with laser welding systems, equipment validation and industrialization.

What You’ll Do

• Act as the technical process owner for automated and manual manufacturing processes within series production.

• Take technical ownership of processes including laser welding, insertion, fastening and manual assembly operations.

• Lead and support FAT, SAT, commissioning, process validation and production ramp-up activities.

• Define equipment acceptance criteria and verify compliance with process, quality, safety, cycle-time and production requirements.

• Develop, validate and maintain robust process parameters and process windows for critical manufacturing operations.

• Plan and execute process qualification and validation, including DOE, capability studies, SPC and MSA / Gage R&R where applicable.

• Define critical process parameters, control limits and reaction plans.

• Monitor production and equipment data to identify trends, deviations and improvement opportunities.

• Define and validate inline monitoring and automated quality-control systems and their correlation with product quality.

• Define process requirements for materials, tolerances, component interfaces, tooling, fixtures and clamping.

• Troubleshoot production and equipment issues and lead structured root-cause investigations.

• Drive corrective actions and continuous improvements in process capability, FPY, scrap, cycle time, OEE and process robustness.

• Support engineering changes and ensure appropriate process re-validation before implementation in series production.

• Maintain key manufacturing documentation including PFMEA, Control Plans, process specifications, validation reports, work instructions and FAT/SAT documentation.

• Train Production, Maintenance and Quality teams on process controls, equipment operation and troubleshooting.

• Work closely with R&D and Product Engineering to improve manufacturability and ensure a robust transition into series production.

What you will bring to Stark

• Degree in Mechanical, Manufacturing, Welding, Materials, Mechatronics Engineering or a related technical field.

• Hands-on experience as a Process or Manufacturing Engineer in an industrial production environment.

• Strong experience with automated manufacturing and assembly equipment.

• Practical experience with industrial laser welding systems is highly desirable and considered a key competence for the role.

• Experience with other manufacturing processes such as fastening, insertion, pressing, dispensing or manual assembly is an advantage.

• Proven experience with FAT, SAT, commissioning, equipment validation and production ramp-up.

• Strong knowledge of process qualification and validation methodologies.

• Experience with Cp/Cpk, SPC, DOE, MSA and Gage R&R.

• Experience defining and optimizing process parameters and robust manufacturing process windows.

• Good understanding of manufacturing tolerances, fixturing, tooling and component interfaces.

• Strong troubleshooting and structured problem-solving skills.

• Experience working with equipment suppliers and system integrators.

• Knowledge of PFMEA, Control Plans and manufacturing quality systems.

• Experience with automated process monitoring and inline quality-control systems is highly desirable.

• Experience in battery, automotive or high-volume automated manufacturing is a strong advantage.

• Knowledge of industrial laser systems and laser safety is an advantage.

• Strong ownership mindset with a practical, hands-on approach.

• Comfortable working in a fast-paced and highly innovative manufacturing environment.

• Strong communication skills and fluent English.

Why work with us?

• The chance to work on a product people are genuinely passionate about

• A fast-growing company with real momentum

• A creative, international team based in Barcelona

• Competitive salary and benefits package

• Direct access to riders, race teams, and the product — this is not a remote-from-the-product role

• Subsidized lunch in our in house restaurant

• Free access to our in-house gym (including weekends!)

• 30 days of paid vacation

At Stark, we don’t just accept difference—we celebrate it, we support it, and we thrive on it for the benefit of our employees, our products, and our community.

We are committed to creating an inclusive environment where everyone can thrive, and we welcome applications from all qualified candidates regardless of race, colour, religion, gender, gender identity or expression, sexual orientation, national origin, disability, or age.