Senior UAV Battery Design Engineer (Pouch Cells & HV) 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.

About The Role: Malloy Aeronautics are looking for an engineer with experience working with pouch cell integration to join our concept development team. This role will focus on the development of batteries from a set of requirements to production product. This role suits an engineer who has a broad skillset across battery design elements and enjoys spending time hands‑on building and testing.

Security Clearance: Ability to hold Security Clearance – 5 years residence in the UK.

What you’ll be doing:

• 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.
• Developing prototype and/or concept battery packs with novel technologies.
• Working with and supporting suppliers to ensure parts are on time and designed to best suit their needs.
• Generating technical documentation, reports, and supporting build guide development.

Essential Skills and Experiences:

• Prior in‑depth experience in battery pack design and cell integration.
• Experience using, designing, integrating and packaging pouch cells.
• Experience with battery thermal management methodologies.
• 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.

Desired Skills and Experiences:

• Experience in high‑performance and/or high pack factor battery applications such as motorsport, aerospace, etc.
• Electrochemical knowledge & experience in lab environment.
• Pack simulation using FEA/CFD packages (thermals, electrical simulation, vibration etc.).
• Experience working with mass critical systems.
• Experience with high vibration applications.
• Familiarity with text‑based programming.
• Knowledge of battery testing standards.

Benefits you may be eligible for:

• Working Environment: 9-day fortnight. 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).
• Mental Health First Aiders.
• Cycle to Work Scheme.
• Casual Dress.
• Bronze Level Armed Forces Covenant which signals our commitment to supporting the Armed Forces.

Why Malloy Aeronautics?

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.

Security and Export Control: Malloy Aeronautics employees 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.

Equal Opportunity Employer: Malloy Aeronautics is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.