Senior Mechanical Design Engineer

Malloy Aeronautics Limited specializes in the development of heavy lift unmanned air vehicles (UAVs) for both civilian and military uses. Located in Berkshire, our operations are notable for their focus on in-house design and manufacturing. This vertical integration means we control the production of most aircraft components on-site, enhancing our ability to innovate and maintain high standards across all stages of development.

We are seeking a seasoned Senior Mechanical Design Engineer to join our R&D team and play a key role in designing drivetrain components such as electrical motors and generators, electronic speed controllers (ESCs), and various rigs and tooling to support both the existing assembly line and new developments. This position requires a high degree of technical proficiency and offers an excellent opportunity to shape our cutting-edge projects.

What you’ll be doing:

• Designing and developing drivetrain components, including motors, generators, and ESCs.
• Creating tooling and rigs to support both assembly lines and new product developments.
• Experience developing parts and structures for weight-constrained applications.
• Building & reviewing 3D models in SolidWorks of composite components, structural assemblies, and other metallic & plastic parts.
• Applying Geometric Dimensioning and Tolerancing (GD&T) principles to ensure precision and manufacturability.
• Collaborating with electrical and mechanical engineers to optimise designs for performance and durability.
• Developing build instructions and technical documentation for manufacturing teams.
• Analysing materials, structural integrity, and lightweight designs for high-performance applications.
• Assessing the right production processes for different parts to ensure cost-effective, high-quality components.
• Considering electrical aspects, such as winding patterns, electrical steel, and creepage/clearance requirements.
• Interface with other engineering groups on collaborative projects to deconflict integration issues and execute against the integration plan.
• Evidence of successful and novel designs created using rapid prototyping techniques.
• Basic FEA knowledge, backed with hand calculations to ensure parts are designed mass efficiently with appropriate safety factors.

Desired Skills and Experiences:

• A degree in Mechanical Engineering or a related field.
• Creativity for new designs, jigs and assembly tools.
• Proficiency in CAD software, with SolidWorks being highly desirable.
• Strong experience with GD&T and design for manufacturing principles.
• Extensive knowledge of electrical rotating machinery (mechanical and electrical aspects).
• Familiarity with bearings, lightweight structural designs, and performance optimisation.
• Excellent problem-solving skills and attention to detail.
• Strong communication and collaboration skills.

Benefits you may be eligible for:

• Company Pension Scheme
• Access to 24 Hour Helpline
• Employee Stock Purchase Plan (BAE Systems Share Incentive Plan)
• Cycle to work scheme
• Additional holiday with long service
• Healthcare cash plan
• 20 Days of Annual Leave + Bank Holidays
• Statutory Sick Pay
• Three-Day Long Weekend Every Fortnight (Fri-Sun)
• Freshly Cooked Lunch on working Fridays
• Casual Dress
• On-Site Parking

Our company benefits from a streamlined process where engineering teams are involved in the entire lifecycle of our UAVs — from initial design through to production. This setup not only speeds up the development process but also improves the efficiency and effectiveness of our product launches. We value professionals who have a background in both research and development (R&D) and design for manufacture, as their expertise is crucial to our rapid and precise product development cycle.

Please be aware that many roles working for Malloy Aeronautics will be subject to both security and export control restrictions. These restrictions mean that factors including your nationality, any previous nationalities you have held, and your place of birth may limit those roles you can perform for the organisation.

Malloy Aeronautics is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. We welcome candidates from all backgrounds and particularly from sections of the community who are currently underrepresented within our industry, including women, ethnic minorities, people with disabilities and LGBTQ+ individuals.

We also want to make sure that our recruitment processes are as inclusive as possible. If you have a disability or health condition (for example dyslexia, autism, an anxiety disorder etc.) that may affect your performance in certain assessment types, please speak to your recruiter about potential reasonable adjustments.

If you have not heard from our recruitment department within 14 days, unfortunately you have not been successful.