Senior Mechanical Design Engineer

at  Malloy Aeronautics Ltd

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.

ABOUT THE ROLE:

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 BEING 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.