Mechanical Design Engineer

Description

This role is based at a state-of-the-art manufacturing and engineering facility in Sedgefield, County Durham.

An exciting opportunity has arisen for a Mechanical Design Engineer to join an established engineering team, working on advanced RF and microwave products from concept through to volume production.

The role offers the opportunity to work with experienced engineers, advanced design tools and in-house RF/mmWave manufacturing capability across telecommunications, aerospace, defence, space and other high-reliability applications.

Purpose of Role

To provide end-to-end mechanical engineering support for advanced RF systems, modules and amplifiers, ensuring mechanical performance, thermal efficiency, reliability, manufacturability, quality and cost requirements are achieved.

Key Duties:

Design precision mechanical components and assemblies, including lightweight enclosures, heatsinks, liquid cooling solutions and waveguide-based architectures.

Develop modular mechanical designs considering mass, volume, mounting interfaces and serviceability.

Ensure designs meet RF, thermal, mechanical and environmental requirements, including EMI shielding, structural stiffness, tolerance control, CTE compatibility, vibration, shock and ingress protection.

Create detailed 2D drawings and 3D CAD models using SolidWorks.

Select suitable materials, finishes and manufacturing processes to support performance, reliability and manufacturability.

Carry out or support thermal analysis, CFD, conjugate heat transfer and FEA for vibration, shock, fatigue and other load conditions.

Work closely with RF, electronics and systems engineers on features affecting RF performance, including cavity geometry, plating, tolerances, materials and precision alignment.

Develop designs for manufacture, assembly and cost reduction using CNC machining, die-casting, additive manufacturing and sheet metal processes.

Produce manufacturing documentation, including BOMs, GD&T drawings and assembly instructions, while maintaining drawing and document control.

Support suppliers and production teams through prototype builds, first article approval and continuous improvement.

Contribute to design reviews, NPI and engineering change processes, including ECN/ECO activity.

Support prototype builds, testing and environmental/reliability testing, including thermal cycling, humidity, vibration, thermal shock and drop testing.

Work with test and process engineering to develop production hardware, jigs and fixtures.

Provide technical support to internal teams, customers and external partners throughout the product lifecycle.

Key Requirements:

Degree or equivalent qualification in Mechanical Engineering.

Strong 2D and 3D CAD skills, preferably SolidWorks.

Experience designing high-precision mechanical components and assemblies within technically demanding or high-reliability environments.

Good understanding of PCB integration, RF shielding and EMI/EMC considerations.

Strong knowledge of materials and manufacturing processes, particularly CNC machining of aluminium alloys and lightweight structures.

Excellent understanding of GD&T and engineering drawing standards, with experience designing machined, cast, moulded, punched or sheet metal parts.

Experience with PDM/PLM systems and engineering change processes.

Strong problem-solving skills, attention to detail and the ability to manage multiple projects and priorities.

Excellent communication skills and the ability to work effectively with multidisciplinary teams, suppliers and customers.

A proactive, hands-on and customer-focused approach.

Desirable Skills and Experience:

Experience in aerospace, defence, space, telecommunications or other high-reliability environments.

Experience with industrial system design.

Experience with FEA and thermal simulation tools, ideally SolidWorks Simulation or SolidWorks Flow.

Familiarity with RF/mmWave products such as waveguides, filters, amplifiers and high-frequency assemblies.

Knowledge of lightweighting and structural optimisation.

Experience with MIL-STD or ECSS design standards and environmental testing such as thermal vacuum or vibration qualification.

Knowledge of RoHS and WEEE compliance.

Experience with supplier development, first article inspection or production readiness.

The Package:

Up to £60,000 per annum depending on experience.

37.5 hour working week.

25 days' holiday plus public holidays, with the option to buy up to 5 additional days.

Contributory pension scheme with up to 8% company contribution.

Life Assurance.

Income Protection Insurance.

SAYE share scheme.

Electric Vehicle (EV) scheme.

Cycle to Work scheme.

Volunteering day.

Learning and development opportunities.

Additional Requirement:

The successful candidate must meet the criteria for UK Government Security Clearance vetting