Design Engineer / Technical Project Lead
Department: Engineering
Reports To: Group CTO
Location: Skypark, Exeter (on-site with customer travel)
Salary: Competitive, dependent on experience
Employment Type: Full-time, Permanent
Salary: 40-60K
About Rapid Fusion
Rapid Fusion is an advanced manufacturing company based in Exeter, Devon, specialising in large-format additive manufacturing (LFAM) systems. We develop robotic 3D printing systems including the Cerberus (containerised military systems) and Gantry (factory floor systems), along with the PE320 pellet extruder and Apollo Zeus commercial manufacturing platform. We work with clients across defence, aerospace, marine, and industrial sectors, delivering cutting-edge manufacturing solutions.
Role Overview
We are seeking an experienced Design Engineer with a strong background in mould tool design to lead technical delivery of our print projects. This customer-facing role owns projects from concept through to delivery, working closely with clients to develop designs, advise on manufacturability, and ensure successful outcomes. You will act as the technical authority on projects, guiding our Sales Engineer on what's achievable and managing the 3D print team to deliver on time and to specification.
The ideal candidate has hands-on experience designing mould tools, patterns, or similar tooling applications, and understands the practical realities of taking a design from screen to finished product.
Key Responsibilities
Design & Technical Leadership
* Develop and refine customer designs for large-format 3D printing, ensuring printability and structural integrity
* Apply mould tooling principles to optimise designs for downstream processes (machining, layup, assembly)
* Conduct design reviews with customers, advising on material selection, build orientation, and design modifications
* Create and maintain CAD models, drawings, and technical documentation for print projects
* Develop print strategies including toolpaths, support structures, and build parameters
Project Management
* Own projects from order through to delivery, managing timelines, budgets, and customer expectations
* Lead and coordinate the 3D print technician team on day-to-day production
* Manage project risks and resolve technical issues as they arise
* Ensure quality standards are met and projects delivered to specification
Customer & Sales Support
* Act as the primary technical contact for customers throughout project delivery
* Support the Sales Engineer during the sales process, providing technical feasibility assessments and design input
* Advise sales on what's achievable, identifying potential challenges early and proposing solutions
* Contribute to quoting by providing accurate time and material estimates based on design complexity
* Build strong customer relationships through technical expertise and reliable delivery
Continuous Improvement
* Identify opportunities to improve design workflows and print processes
* Develop design guidelines and best practices for large-format additive manufacturing
* Contribute to the company's technical knowledge base and training materials
Requirements
Essential:
* Demonstrable experience in CAD design, ideally using Fusion 360 or similar
* Background in mould tool design, pattern making, or tooling applications
* Understanding of manufacturing processes and design for manufacture principles
* Proven ability to manage projects and deliver to deadlines
* Strong problem-solving skills with a practical, solutions-focused approach
* Excellent communication skills with the ability to explain technical concepts to non-technical audiences
* Experience working directly with customers in a technical capacity
* Full UK driving licence
Desirable:
* Experience with composites manufacturing, GRP/CFRP layup, or related processes
* Familiarity with additive manufacturing, particularly large-format or pellet extrusion systems
* Knowledge of CAM software and CNC machining principles
* Experience in defence, aerospace, or marine sectors
* Project management qualification (PRINCE2, APM, or similar)
What We Offer
* Opportunity to work with cutting-edge robotic 3D printing technology
* Be part of a fast-growing company at the forefront of advanced manufacturing
* Work on diverse projects across defence, aerospace, marine, and industrial sectors
* Collaborative environment where your contribution makes a real difference
* Career development opportunities as the company scales
* Pension scheme
* 21 days annual leave plus bank holidays