Principal Design Engineer - Suspension in Royal Leamington Spa

We are seeking an experienced Principal Design Engineer to join a global mechanical design team on a contract basis. You will lead the design and development of vehicle and suspension systems, from initial concept through to production-ready solutions. This role involves taking ownership of mechanical systems or complete products, managing a small team of designers, and collaborating closely with other engineering disciplines (e.g., simulation, manufacturing) to deliver solutions that meet component, system, product, and client requirements.

Responsibilities

• Lead concept and detailed 3D mechanical design of systems, assemblies, and complex components (e.g., subframes, suspension knuckles, control arms, tie rods, pitman arms).
• Perform detailed design activities, including basic stress calculations, FMEA, 2D detailing, layouts, and tolerance stack analyses as needed.
• Work closely with FEA and simulation teams to validate designs against requirements.
• Collaborate with manufacturing and process engineers to ensure DFMA compliance.
• Manage Bills of Materials (BOMs).
• Produce technical reports, documentation, and other project deliverables.
• Liaise with suppliers and internal teams to ensure timely information flow and resolution of client queries.
• Coach and mentor junior design engineers in best practices.
• Step into lead designer or small-to-medium project team leadership roles as required.
• Stay informed on relevant market trends and sector developments.

Essential Skills and Experience

• Degree (BEng/MEng) in Mechanical Engineering or equivalent, plus substantial relevant experience (or equivalent technical background).
• Proven track record in mechanical design engineering, with a strong focus on vehicle/chassis systems.
• Specialised knowledge in at least one key area: suspension design, subframe design, or suspension/steering components.
• Strong grasp of core mechanical engineering principles, including the ability to interpret and apply FEA/CFD results.
• Good understanding of suspension/steering fundamentals, vehicle dynamics, NVH, and durability considerations.
• Solid knowledge of manufacturing processes and their design implications, with practical DFMA experience.
• High proficiency in producing and checking 2D technical drawings, with advanced GD&T competency.
• Experienced CATIA V5 user (essential).
• Familiarity with PLM systems (Windchill preferred).
• Experience leading small teams.
• Advanced Microsoft Office skills.

Personal Attributes

• Confident, proactive, and adaptable - able to lead in challenging situations to deliver results.
• Strong technical communication and report-writing skills in English.
• Excellent problem-solving and analytical abilities.
• Organised, with the capacity to manage multiple priorities and tight deadlines.
• Willing and able to travel occasionally (UK and overseas) for supplier/customer meetings.

What We Offer

• Hybrid working flexibility (office/home mix, to be discussed).
• Opportunity to work on innovative, sustainable engineering projects in a supportive environment.
• Competitive contractor day rate (negotiable based on experience).

This is a contract position, and applications are welcome from experienced contractors. If shortlisted, we will discuss IR35 considerations further and issue any required status determination. To apply, please submit your CV and a brief cover note outlining your relevant vehicle/suspension design experience.