Mechanical Design Engineer

Overview:
As a Mechanical Design Engineer at Windracers, you will be responsible for the mechanical design and development of advanced cargo drone systems. You will translate system requirements into robust, lightweight, and manufacturable designs, supporting the entire lifecycle from concept through prototyping, testing, and production. This role requires strong CAD skills, a solid understanding of aerospace mechanical design principles, and experience designing structural components and mechanisms. The ideal candidate is someone who can take ownership of all aspects of development activities working closely with internal teams and, where required, external stakeholders.

Key Responsibilities:

Mechanical Design & CAD Modelling

• Create detailed 3D CAD models and 2D drawings for UAV components, assemblies including primary structures, payload integration solutions, and aircraft mechanisms and physical subsystems.
• Take on design tasks from concept to production for the main structural assemblies of the aircraft aimed at improving performance, robustness and reducing cost, while meeting developing customer requirements.
• Design and develop mechanisms for systems such as landing gear, suspension, cargo handling, control surfaces, and customer payload integration.
• Maintain configuration control and design documentation across the product lifecycle.

Analysis

• Perform preliminary structural and kinematic analyses to ensure assemblies meet strength, motion, and durability requirements.
• Collaborate with simulation engineers to refine designs under aerodynamic, structural, and environmental loads.
• Iterate designs based on test results, feedback, and trade-off studies.

Prototyping & Testing Support

• Support the fabrication and assembly of prototypes, ensuring designs are manufacturable.
• Participate in ground and flight testing campaigns, troubleshooting mechanical and mechanism issues and implementing improvements.
• Document design changes and lessons learned to feed into continuous development.

Cross-Functional Collaboration

• Work closely with aircraft systems, propulsion, avionics, and software engineers to ensure designs meet system-level requirements.
• Contribute to design reviews with clear communication of trade-offs, risks, and proposed solutions.
• Work closely with and act on feedback from internal manufacturing, manufacturing partners as well as customers and the Windracers Operations Team.

Manufacturing & Supply Chain Support

• Prepare detailed manufacturing drawings, BOM and specifications for both in-house fabrication and external manufacturing partners and suppliers.
• Ensure designs align with cost, quality, and lead-time considerations.
• Collaborate with suppliers and internal Manufacturing to resolve technical queries and improve manufacturability.

Qualifications:

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related field.
• 5+ years of experience in mechanical design, preferably in aerospace, UAVs, or similar fields.
• Proficiency with CAD software (SolidWorks, and SolidWorks PDM preferable).
• Experience designing lightweight structural assemblies in a similar sector (UAVs, Aerospace, automotive/motorsport).
• Knowledge of materials and manufacturing processes relevant to lightweight structures. Experience with sheet metal, bonded and riveted assemblies highly desirable, experience with composite assemblies will be considered as well.