Mechanical Design Engineer

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
You will be responsible for the concept and detailed design of the hardware integration Such as:

Engine mounting to frame
Engine vibration isolation
Concept and deign 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