Overview
Job title: Lead / Senior Mechanical Design Engineer (Drivetrain) at Malloy Aeronautics Ltd.
The Malloy Aeronautics Team: Malloy Aeronautics Limited specializes in the development of heavy lift unmanned air vehicles (UAVs) for both civilian and military uses. Located in Berkshire, our operations focus on in-house design and manufacturing, enabling vertical integration to control production of most aircraft components on-site for rapid innovation and consistent quality.
About the Role
We are seeking an accomplished Lead or Principal Mechanical Design Engineer to own the mechanical design for drivetrain components such as electrical motors and generators, electronic speed controllers (ESCs), and the associated rigs and tooling. You will lead one or more junior designers, ensure quality, consistency, and timely delivery of designs, and liaise closely with mechanical, electromagnetic, and thermal analysts both within the team and externally. This is a hands-on technical leadership role with significant influence over our most advanced R&D projects.
Security clearance eligibility – 5 years residence in the UK is required.
What You’ll Be Doing
* Taking ownership of the mechanical design across drivetrain components, including motors, generators, and ESCs.
* Leading, mentoring, and reviewing the work of junior designers to ensure high-quality outputs.
* Creating tooling and rigs to support both assembly lines and new product developments.
* Designing for weight-constrained applications and optimising structural efficiency.
* Building and reviewing 3D models in SolidWorks of composite components, structural assemblies, and other metallic and plastic parts.
* Applying Geometric Dimensioning and Tolerancing (GD&T) principles to ensure precision and manufacturability.
* Liaising with mechanical, EM, and thermal analysts to integrate analysis outputs into design decisions.
* Developing build instructions and technical documentation for manufacturing teams.
* Analysing materials, structural integrity, and lightweight designs for high-performance applications.
* Selecting production processes for 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.
* Demonstrating novel, successful designs using rapid prototyping techniques.
* Basic finite element analysis (FEA) knowledge, backed with hand calculations to ensure parts are designed mass-efficiently with appropriate safety factors.
Essential Skills and Experiences
* A degree in Mechanical Engineering or a related field is mandatory.
* Proven leadership in guiding junior designers and owning end-to-end mechanical design.
* 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.
Benefits
* Bronze Level Armed Forces Covenant
* Company Pension Scheme
* Access to 24 Hour Helpline
* Employee Stock Purchase Plan (BAE Systems Share Incentive Plan)
* Cycle to work scheme
* Additional holiday with long service
* 20 Days of Annual Leave + Bank Holidays
* Statutory Sick Pay
* Freshly Cooked Lunch on working Fridays
* Casual Dress
* On-Site Parking
Important Notices
Malloy Aeronautics may impose security and export control restrictions on roles. Nationality, previous nationalities, or place of birth may affect eligibility.
Malloy Aeronautics is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees, including women, ethnic minorities, people with disabilities, and LGBTQ+ individuals.
If you have a disability or health condition that may affect performance in certain assessments, please speak to your recruiter about potential reasonable adjustments.
Note: If you have not heard from our recruitment department within 14 days, you have not been successful.
Privacy note: Malloy Aeronautics and BAE Systems will collect and process information about you in compliance with data protection laws. For details about how we use and disclose your personal information, please refer to the privacy notice.
#J-18808-Ljbffr