Job Description
Job Title: Senior Design Engineer
Department: New Product Development (NPD)
Reports To: Head of Design / Design Manager
Location: Lancashire - Onsite Role
Position Purpose
A market leading lighting manufacturer is seeking an experienced and highly skilled Senior Design Engineer to join their innovative NPD team. This role is instrumental in the end-to-end development of cutting-edge, sustainable lighting products - from initial concept to full production. The successful candidate will possess a strong foundation in mechanical or product design, a keen eye for detail, and a passion for delivering exceptional and commercially viable solutions.
Key Responsibilities
* Lead the delivery of complex, large-scale projects in strict accordance with the NPD Gate process.
* Design and develop products that meet all project specifications, timelines, and quality standards.
* Demonstrate a thorough understanding of project requirements and communicate design rationale clearly, challenging and refining specifications where appropriate.
* Deliver safe, reliable, and commercially successful design solutions using tools such as FMEA.
* Accurately complete all required documentation to support design outputs.
* Utilize a range of design tools including sketches, models, prototypes, and 3D CAD to effectively communicate ideas.
* Create precise CAD and PLM data in line with best practice standards.
* Develop accurate, costed Bills of Materials (BoMs) for all new designs.
* Investigate and address cost variances, proposing solutions and communicating with key stakeholders.
* Produce production-ready components and assemblies, integrating insights from research into product technologies and structures.
* Continuously improve existing products and processes, identifying opportunities for innovation and efficiency.
* Enhance installation methodologies by developing intuitive, safe, and user-friendly solutions supported by physical samples and clear instructions.
* Apply root cause analysis to resolve design issues, implementing robust corrective actions.
* Mentor and support Trainee Design Engineers and Apprentices, fostering their technical and professional growth.
* Stay informed on industry developments, trends, and competitor activity to ensure the business remains ahead of the curve.
Essential Skills & Qualifications
* Degree or equivalent qualification in Mechanical or Product Design.
* 5+ years of industry experience with a track record of successfully delivering complex projects on time, within specification and budget.
* Proficient in designing tooled components (plastic moulding, die-casting, extruded profiles in plastic and aluminium).
* Experienced in light gauge sheet metal design and fabrication.
* Strong 3D CAD skills (ideally Solid Edge), with the ability to produce detailed drawings and tolerance stacks for both mechanical and electrical assemblies.
* Confident in using Microsoft Office Suite and other relevant software tools.
* Skilled in creating prototypes (handmade, sketch, CAD, physical) to test and refine concepts.
* Strong understanding of customer needs and user experience (installer, end-user, specifier).
* Excellent commercial awareness and ability to balance cost, functionality, and aesthetics.
* Demonstrated ability to lead design projects with a creative and solutions-focused mindset.
Desirable Skills
* Knowledge of material science and properties.
* Experience using FEA tools for stress and failure analysis.
* Previous experience in luminaire development.
* Familiarity with IEC 60598-1 and relevant lighting safety standards.
* Experience with Teamcenter PLM.
* Rendering and visualization skills using tools like Keyshot.
* Experience with ray tracing and optical design.
* Knowledge of sustainable design and manufacturing practices.
Key Behaviours
* Strong communication and interpersonal skills.
* Excellent problem-solving and analytical abilities.
* Organised, adaptable, and self-motivated.
* A collaborative team player with effective leadership skills.
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