Senior Engineer - Composites & CAE in Surrey

b Overview /b p In this role you will be the specialist link between composite material testing, manufacturing processes and CAE. You will drive robust material characterisation, manufacturing simulation and technical analysis to enable efficient virtual development of McLaren composite structures. You will collaborate with Materials and CAE teams to ensure material behaviour and manufacturing data are accurately represented in the CAE toolchain. This position focuses on delivering defined work packages and high-quality outputs within a fast-paced, tech-driven environment. /p b Pay / Benefits /b ul li Structured career development framework /li li 25 days’ holiday plus bank holidays /li li Enhanced company pension scheme /li li Discretionary annual bonus /li li Private medical insurance and health cash plan /li li Life assurance benefit /li /ul b Responsibilities /b ul li Deliver material test and characterisation activities for composite constituents and laminates /li li Develop test programmes to establish mechanical/physical behaviour for CAE and manufacturing simulation /li li Analyse test results to identify trends, anomalies and root causes /li li Support development of CAE-ready material data and models /li li Deliver manufacturing simulations for composite structures (draping, forming, moulding) and assess manufacturing impact on fibre orientation, thickness, defects and distortion /li li Translate manufacturing simulation outputs for use in structural CAE /li li Support validation of manufacturing simulation methodologies for new technologies /li li Collaborate with manufacturing engineers to align virtual predictions with production processes /li li Develop understanding of material–manufacturing–CAE relationships and integrate material information into structural models /li li Investigate manufacturing variability and defects on structural performance /li li Provide technical insights to ensure virtual models reflect production-intent structures /li li Support development of new methodologies for composite materials and manufacturing simulation /li li Investigate emerging materials/technologies for future McLaren applications /li li Apply first principles and engineering judgement to validate simulations and aid decision-making /li li Contribute to automation and improved workflows for material testing, data processing, and CAE integration /li li Produce high-quality technical reports and recommendations /li /ul b Key requirements /b ul li Significant technical experience in composite materials testing and/or composite manufacturing CAE /li li Strong practical experience in composite material characterisation and test methods /li li Strong knowledge of composite manufacturing processes (prepreg, RTM, infusion, compression moulding) /li li Experience with composite manufacturing simulation, particularly draping and forming analysis /li li Understanding of how manufacturing processes influence structural performance and CAE inputs /li li Knowledge of laminate theory, fibre orientation, defects and failure mechanisms /li li Experience translating material test results into simulation models and engineering allowables /li li Strong analytical capability using first principles and engineering judgement with CAE /li li Good understanding of finite element analysis and its application to composites /li li Strong communication skills for cross-functional collaboration with materials, CAE, manufacturing, suppliers and academia /li li Delivery-focused with a track record of on-time delivery in high-pressure environments /li li Ability to explain technical findings to both specialists and non-specialists /li li Willingness to engage in debate and discussion /li li Empathy and active listening in cross-functional teams /li li Ability to lead a small, focused team when needed /li li Ambitious, self-motivated and well organized /li /ul ul li strong collaboration /li li clear communication /li li delivery focus /li li composite materials testing /li li composite manufacturing CAE /li li draping and forming analysis /li /ul