Fuel System Design Engineer (High-Performance Automotive) in Guildford

Expleo is a trusted partner for end-to-end, integrated engineering, quality services and management consulting for digital transformation. We help businesses harness unrelenting technological change to successfully deliver innovations that will help them gain a competitive advantage and improve the everyday lives of people around the globe. An exciting opportunity has arisen for a Fuel System Design Engineer to join a high-performance automotive engineering environment, supporting the design, development, integration, and validation of advanced fuel system architectures for next-generation vehicle programmes. This role will focus on the end-to-end development of fuel system components and assemblies, from concept definition through to prototype, validation, and production release. The successful candidate will work across multidisciplinary engineering teams to deliver high-quality, manufacturable fuel system solutions that meet demanding performance, packaging, durability, regulatory, and timing targets. The position requires strong mechanical design capability, hands-on engineering understanding, and experience working with fluid systems in high-performance automotive or related engineering sectors.

Responsibilities

• Design and develop complete fuel system architectures and associated components for high-performance vehicle applications.
• Lead or support development of:
• Fuel tank assemblies
• Fuel filler systems
• Fuel pumps and filtration systems
• Fuel lines, manifolds, and sensors
• EVAP systems and charcoal canister integration
• Fuel retention and mounting systems
• Fuel metering and control components
• Develop detailed 3D CAD models, assemblies, and engineering drawings for fuel system components and installations.
• Perform vehicle integration and packaging studies to ensure compatibility with overall vehicle architecture and packaging constraints.
• Support concept generation and evaluation for new fuel system technologies and layouts.
• Use engineering calculations, modelling tools, and simulation methods to size and optimise fuel systems and fluid control components.
• Conduct fluid system analysis using CFD tools, FEA methods, and thermal and flow simulations.
• Evaluate system performance, durability, manufacturability, and reliability.
• Support tolerance analysis, stack-up assessments, and DFMEA activities.
• Develop component and system-level validation plans and support execution of testing activities.
• Collaborate with test and validation teams on rig testing, pressure and leak testing, environmental and durability testing, and system verification and issue resolution.
• Produce and maintain engineering documentation including CAD data (2D & 3D), BOM structures, engineering release documentation, technical specifications, change requests, and issue tracking.
• Support engineering release processes ensuring designs meet internal standards, gateway deliverables, and regulatory requirements.
• Work closely with vehicle integration teams, manufacturing and prototype build teams, suppliers and external partners, test and validation engineers, purchasing and programme management teams.
• Participate in design reviews and technical discussions to ensure robust and optimised engineering solutions.
• Support supplier management activities, including technical reviews and component development coordination.

Qualifications

• Bachelor’s or Master’s degree in Mechanical Engineering, Automotive Engineering, Mechatronics, or a related engineering discipline.
• Strong understanding of mechanical systems and fluid system engineering principles.

Essential skills

• Proven experience designing and developing automotive or high-performance fuel systems and associated components.
• Strong understanding of fluid systems, fuel routing and packaging, EVAP systems, pumps, valves, and filtration systems, and fuel storage and delivery systems.
• Proficiency in CAD software such as CATIA V5 or equivalent 3D CAD platforms.
• Experience producing detailed component and assembly models, manufacturing drawings, and GD&T-compliant engineering documentation.
• Experience using engineering analysis and modelling tools such as ANSYS, Mathcad, CFD / FEA software.
• Ability to perform engineering calculations and support system optimisation through simulation-driven design.
• Strong understanding of DFM (Design for Manufacture), DFMEA, engineering release processes, BOM management, and product development lifecycle activities.
• Familiarity with automotive standards and engineering documentation practices.
• Strong communication and collaboration skills.
• Ability to work effectively both independently and within cross-functional engineering teams.
• Proactive approach to problem solving and continuous improvement.

Experience

• Proven experience in fuel system design within automotive, motorsport, aerospace, commercial vehicle or other high-performance engineering sectors.
• Experience developing mechanical and fluid systems from concept through to production release.
• Experience supporting prototype builds, system integration, and validation activities.
• Hands-on experience working with manufacturing, suppliers, and test teams.
• Experience managing engineering changes and technical issue resolution throughout programme delivery.
• Exposure to high-performance or low-volume vehicle development environments is advantageous.

Benefits

• Collaborative working environment – we stand shoulder to shoulder with our clients and our peers through good times and challenges.
• We empower all passionate technology loving professionals by allowing them to expand their skills and take part in inspiring projects.
• Expleo Academy - enables you to acquire and develop the right skills by delivering a suite of accredited training courses.
• Competitive company benefits.
• Always working as one team, our people are not afraid to think big and challenge the status quo.
• As a Disability Confident Committed Employer we have committed to ensuring our recruitment process is inclusive and accessible, communicating and promoting vacancies, offering an interview to disabled people who meet the minimum criteria for the job, anticipating and providing reasonable adjustments as required, and supporting any existing employee who acquires a disability or long term health condition, enabling them to stay in work.
• We are an equal opportunities employer and welcome applications from all suitably qualified persons regardless of their race, sex, disability, religion/belief, sexual orientation or age. We treat everyone fairly and equitably across the organisation, including providing any additional support and adjustments needed for everyone to thrive.