Senior 3D Design Engineer in Maidenhead

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.

This role suits an engineer who has a broad skillset across battery design elements and enjoys spending time hands-on building and testing.

• Ability to hold Security Clearance – 5 years residence in the UK
• Leading the physical design of Malloy’s battery platforms developing packs from a concept stage to production.
• Interface with other engineering groups on collaborative projects to deconflict integration issues and execute against project plans.
• Developing test and validation plans for battery packs, and analysing test data to refine pack design.
• Generating technical documentation, reports, and supporting build guide development.
• Prior in-depth experience in battery pack design and cell integration.
• Experience using, designing, integrating and packaging pouch cells.
• Knowledge of cell connection methodologies including laser welding.
• Experience with a wide variety of production processes including but not limited to lathe, 3-5 axis machining, water jet, laser cut, punch, bending, welding, casting, various 3D printing types and injection moulding.
• Experience using CAD software, ideally SolidWorks.
• Experience designing for high voltage applications and relevant practical high voltage training (preferably SAP/level 3).
• Knowledge of project lifecycle management, developing requirements, and working in a gated design environment.
• Experience in high-performance and/or high pack factor battery applications such as motorsport, aerospace, etc.
• Pack simulation using FEA/CFD packages (thermals, electrical simulation, vibration etc.).
• Familiarity with text-based programming.
• Knowledge of battery testing standards.

Company benefits include:

• Free parking, free lunch on working Fridays, fruit twice a week, tea and coffee.
• Company Pension Scheme.
• Discretionary Employee Incentive Bonus Scheme.
• Employee Share Incentive Plan (BAE Systems).
• Company Sick Pay.
• Maternity and Paternity enhanced Leave.
• Healthcare Cash Plan including Virtual GP, Dental Cover, Vision Cover, Discounted Gym Membership, and much more! Free coverage for children under 2 years old.
• 20 days Annual Leave, increasing with long service.
• Employee Assistance Programme (24hr Helpline).
• Cycle to Work Scheme.
• Casual Dress.

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. 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. We celebrate diversity and are committed to creating an inclusive environment for all employees. If you have a disability or health condition that may affect your performance in certain assessments or interviewing, please speak to your recruiter about potential reasonable adjustments.

Malloy Aeronautics and BAE Systems may process information about you that may be subject to data protection laws.