Working pattern: 9-day fortnight, averaging 37.5 hours per week
About the Opportunity
Certo is looking for an experienced Lead Rotor System CAE Engineer to take technical ownership of the mechanical performance and development of a key rotor head assembly within its rotor system design team.
This is a hands-on engineering R&D role combining advanced structural Computer-Aided Engineering (CAE), mechanical design, aerodynamic analysis, physical testing and technical leadership.
Working within a small, established design office, you will play a key role in developing next-generation rotor systems, taking complex mechanical assemblies from concept through detailed design, simulation, physical validation and certification support.
You will lead engineering analysis and validation activities, establish and improve CAE methods, mentor other engineers and work closely with manufacturing teams, suppliers and test engineers to deliver safe, reliable and high-performance aerospace systems.
Key Responsibilities
- Take full technical ownership of the rotor head system, leading its development from initial concept through detailed design, analysis, testing and certification support.
- Develop and manage the Design Verification Plan (DVP), covering simulation, test mules, test rigs, prototypes and production release.
- Apply first-principles calculations and mathematical modelling to determine initial loads, degrees of freedom, system layouts and component sizing.
- Develop aircraft and system load cases, requirements and acceptance criteria, ensuring requirements flow down to individual components.
- Apply a V-model systems development approach, connecting project definition and engineering development with physical validation.
- Perform detailed structural analysis of complex mechanical systems using industry-standard aerospace FEA solvers.
- Carry out linear and nonlinear stress analysis, aeroelastic loading, structural dynamics, frequency response analysis, fatigue and life calculations.
- Support multidisciplinary CAE activities, including multibody dynamics, aerodynamic loading (CFD), optimisation and advanced analysis methods.
- Develop internal CAE processes, modelling guidelines, solver templates, material models and technical documentation standards.
- Identify opportunities to improve engineering tools, analytical methods and design processes.
- Plan and support physical development testing, including defining test requirements, designing bespoke test rigs and fixtures, and selecting instrumentation.
- Correlate simulation predictions with physical test results, investigate discrepancies and conduct root cause analysis.
- Provide technical leadership to a small team of engineers, offering direction, mentoring and support for professional development.
- Lead formal design reviews and technical risk assessments throughout the product development lifecycle.
- Collaborate with manufacturing teams, suppliers and external partners to ensure designs are practical, producible and robust.
Required Skills and Experience
- Degree in Aerospace Engineering, Mechanical Engineering or a related discipline.
- Significant experience in aerospace, rotorcraft or complex mechanical systems design.
- Proven experience in the analysis and development of rotor head control assemblies.
- Extensive experience in advanced structural CAE techniques using aerospace-accredited FEA solvers, including coupled mechanical and aerodynamic behaviour.
- Strong analytical skills, with extensive experience in detailed engineering calculations and first-principles problem-solving.
The Ideal Candidate
We are looking for an engineer who combines rigorous analytical thinking with practical engineering judgement.
You should be comfortable taking ownership of complex technical challenges, questioning conventional approaches and developing innovative solutions. You will also be a collaborative technical leader who enjoys mentoring others, improving engineering capability and delivering high-quality results across multiple programmes.
- 25 days' annual leave plus bank holidays.
- British citizenship or a valid British passport.
- Ability to work on-site in Frome, Somerset.
- A valid UK driving licence.
- Willingness to travel occasionally within the UK and internationally.
Why Join Certo?
This is an opportunity to take technical ownership of a critical aerospace assembly and influence the development of next-generation rotor systems.
You will have the opportunity to combine advanced simulation, hands-on engineering validation and technical leadership within a collaborative design environment, helping shape the methods, designs and engineering capabilities behind future aircraft programmes.
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Senior CAE Engineer in Frome employer: Certo Aerospace Ltd
Certo Aerospace Ltd offers an exceptional work environment for Aerospace Workshop Technicians in Frome, Somerset, where innovation meets collaboration. With a strong focus on employee growth and hands-on experience in prototype aircraft assembly and testing, team members enjoy a supportive culture that encourages skill development and teamwork. The unique opportunity to work closely with design and flight test engineers ensures that every day brings meaningful challenges and rewards.
