Location: Fareham (PO15 5TX, on-site/hybrid)
Job Type: Full-time | Permanent
Industry: Aerospace, UAV/UAS, Advanced Manufacturing & Production
Salary: DOE
Join the Future of Flight Windracers is seeking a highly experienced Senior or Principal Design Engineer to lead the design and integration of powertrain systems into our advanced Unmanned Aerial Vehicles (UAV) platforms. This is a key contributor role where you'll drive concept and detailed design of engine mounting, vibration isolation, cooling systems, and ancillary packaging. You'll collaborate across disciplines delivering robust, efficient, and innovative solutions that meet performance, safety, and regulatory standards.
Key Responsibilities
* Lead design and development of engine integration systems for UAV platforms
* Create CAD models and detailed drawings using SolidWorks and PDM
* Design engine mounts, cooling baffles, cowlings, exhaust systems, and power take-off assemblies
* Conduct FEA and simulate loads, stresses, and vibration isolation
* Collaborate with cross-functional teams: airframe, autopilot, test, manufacturing, and QA
* Mentor junior engineers and contribute to continuous improvement initiatives
* Ensure compliance with industry standards and manage project risks and costs
* Support testing, validation, and documentation of integrated systems
Key Deliverables
* Engine mounting to frame
* Engine vibration isolation
* Concept and design of engine mounting frame
* Engine frame to fuselage attachment
* Packaging of ancillary components, exhaust, fuel system and electronics
* Design of cylinder / head cooling baffles to ensure efficient air cooling
* Design of engine cowlings to ensure engine is protected and drag is minimised whilst airflow is optimised for cooling
* Reduction drive bracket and installation
* Power-take-off and propeller mounting solution
* Loom layout and power connection
* Fuel hose layout and connections
What You'll Bring
* In-depth knowledge of relevant engineering principles, tools, and methodologies.
* Proficient in professional 3D CAD software, specifically SolidWorks and familiarity with other design tools, including SolidWorks PDM.
* Experience of FE analysis and ability to simulate structures and calculate loads and stresses.
* CFD experience would be beneficial but not essential.
* Experience of designing mechanical structures to house rotating / reciprocating machinery like combustion engines / transmissions etc.
* Experience of combustion engine and or transmission design would be beneficial.
* Good knowledge of materials and manufacturing processes including fabrication, machining and casting.
* Strong analytical, problem-solving, and leadership skills.
* Degree (or equivalent experience) in Mechanical or related Engineering discipline.
* Ideally a master's or further educational or professional development within your field to demonstrate continued professional development.
* 8+ years in mechanical design, preferably in aerospace, automotive, or UAV sectors.
* Passion for aerospace, drones and/or UAV.
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