About Us:
At Defy Aerospace, we are building next-generation unmanned aerial systems (UAS) designed for demanding environments and real-world applications. Our engineers take ownership of complete UAV design engineering — spanning structures, subsystems, integration, and compliance — while working in a fast-paced, innovation-driven environment.
We are seeking a Design Engineer with 2-5 years of experience to deliver design engineering activities across the UAV program in the UK.
Key responsibilities:
* Take ownership of UAV design engineering from concept through prototyping and testing.
* Lead structural and subsystem design, covering:
-External geometry (skins, aerodynamic surfaces, control surfaces).
-Internal layouts (spars, ribs, bulkheads, payload & battery bays, mounting trays).
* Develop detailed 3D CAD models, assemblies, and 2D drawings with GD&T using CATIA V5 / 3DEXPERIENCE (mandatory).
* Design composite sandwich structures (carbon fibre + honeycomb/foam cores) and metallic structures (CNC-machined aluminium/titanium).
* Define load paths and structural concepts (wing box, fuselage frames, landing gear attachments).
* Integrate propulsion mounts, avionics racks, payload hardpoints, and access hatches into the structure.
* Perform preliminary structural analysis (stiffness, stress, buckling) and work with analysis engineers for FEA/CFD validation.
* Manage mass properties and CG discipline across components and subsystems.
* Generate and maintain BoMs, revision control, and design documentation in line with aerospace gated processes.
* Follow strict documentation and data discipline: ensure drawings, BoMs, weight reports, and design changes are traceable and released through proper processes.
* Participate in PDR, CDR, TRR and deliver design packages to required standards.
* Support tooling design, prototyping, and hands-on testing during builds and flight trials.
Required Qualifications:
* Bachelor’s/Master’s degree in Aerospace, Mechanical, or Structures Engineering.
* 2-5 years of experience in UAV/aircraft design engineering.
* Hands-on expertise in CATIA V5 / 3DEXPERIENCE (mandatory), including surface modelling.
* Strong knowledge of composite and metallic design/manufacturing methods (pre-preg, autoclave, CNC).
* Experience designing primary load-carrying structures (spars, ribs, bulkheads).
* Understanding of FEA processes (ANSYS/NASTRAN/Abaqus) and CFD workflows.
* Proven experience in documentation, change management, and gated aerospace processes (PDR, CDR, TRR).
Join us and :
* Own the complete design of next-gen UAVs
* Work at the intersection of innovation and applied aerospace technology.
* Join a small, high-impact team building systems designed to perform in challenging conditions.
* Contract: Six months (extendable)
We strongly encourage UK-based engineers — including those on Graduate or PSW visas — to apply.
This role offers the opportunity to gain hands-on, industry-relevant experience working on next-generation aerial systems alongside a focused, high-performance engineering team.