POSITION: SENIOR MECHANICAL DESIGN ENGINEER

JOB TYPE: FULL TIME

LOCATION: LLANGEFNI, NORTH WALES

The Senior Mechanical Design Engineer plays a key role in the development, optimisation and certification of mobile machinery and defence‑sector equipment. This position combines advanced mechanical design, structural analysis, materials engineering and regulatory alignment to ensure products meet stringent defence, customer and international requirements. The role spans concept development through production, including technical documentation, risk management and support for customer acceptance and audit activities.

Key Responsibilities

Mechanical Design & Engineering

• Lead the design and development of mechanical systems for mobile machinery from concept to production.
• Integrate hydraulic systems into mechanical designs, ensuring performance, safety and compatibility.
• Create 3D models and detailed engineering drawings using PTC Creo.
• Conduct FEA, stress analysis and simulation‑driven design to validate structural integrity.
• Collaborate with electrical, controls, manufacturing and quality teams to deliver fully integrated systems.
• Ensure manufacturability, cost‑effectiveness and adherence to defence‑sector engineering standards.
• Support prototype builds, testing, validation and troubleshooting of design and field issues.
• Maintain BOMs in ERP (Navision/Business Central) and PLM (Windchill).

Regulatory Alignment & Technical Documentation

• Ensure products meet EU and UK regulatory frameworks, including CE and UKCA marking for mobile machinery.
• Carry out conformity assessment processes, including technical documentation, risk assessments and Declarations of Conformity.
• Maintain up‑to‑date knowledge of applicable directives and regulations (e.g., Machinery Directive/Regulation).
• Prepare and maintain technical files, product dossiers and supporting evidence for internal and external audits.
• Coordinate with notified bodies or approved bodies when required.
• Verify that product labelling, safety information and instructions for use meet EU/UK/foreign requirements.
• Support customer acceptance activities, including inspections, verification testing and formal compliance evidence.

• Support defence‑sector traceability, documentation control and customer‑specific quality requirements.
• Support environmental and durability testing.
• Support customer demonstrations.
• Ensure engineering outputs meet defence standards, safety expectations and contractual obligations.
• Provide structured, audit‑ready documentation for defence customers and authorities.

Structural & Material Optimisation

• Perform design optimisation to improve performance, durability and efficiency.
• Conduct topology, shape and size optimisation to minimise weight while maintaining required safety factors.
• Use simulation‑driven design to refine geometry and load paths.
• Lead material optimisation activities, selecting materials based on performance, cost, sustainability and manufacturing constraints.
• Develop material selection criteria using engineering trade‑off analysis and performance indices.
• Collaborate with suppliers and materials specialists to evaluate new materials and technologies.
• Build and validate simulation models to support optimisation decisions.
• Support prototype builds and conduct mechanical testing to validate optimisation outcomes.
• Analyse test results and iterate designs based on empirical data.

Risk Management

• Conduct and document FMEA, PFMEA and DFMEA in line with regulatory and defence‑sector expectations.
• Ensure risk‑reduction measures are implemented, verified and documented throughout the design lifecycle.

Typical Experience & Qualifications

Education

• Bachelor’s degree in Mechanical Engineering, Automotive Engineering, Aerospace Engineering or related discipline.
• Master’s degree or postgraduate study in mechanical design, structural engineering or materials engineering (desirable).
• Additional training in CE/UKCA conformity assessment, functional safety or defence‑sector standards (advantageous).

Professional Experience

• Typically 5–10+ years of mechanical design experience in mobile machinery, heavy equipment, defence systems or similar regulated industries.
• Proven experience delivering mechanical systems from concept through production, including prototyping and validation.
• Experience preparing technical documentation for CE/UKCA marking and working with notified/approved bodies.
• Strong background in FEA, structural analysis and simulation‑driven design.
• Experience with structural optimisation and material selection for performance‑critical components.
• Familiarity with defence‑sector or highly regulated industry documentation, traceability and quality expectations.
• Experience supporting customer acceptance testing and inspections.

Technical Skills

• Proficiency in PTC Creo and associated CAD workflows.
• Strong capability in FEA tools for stress, strain, fatigue and optimisation.
• Understanding of hydraulic systems and their integration into mechanical designs.
• Bonus: Knowledge of low‑voltage hydraulic control systems and CANBUS‑based control architectures.
• Familiarity with ERP/PLM systems (Navision/Business Central, Windchill).
• Strong understanding of EU/UK regulatory frameworks and supporting standards.
• Knowledge of materials engineering and advanced material technologies.

Soft Skills

• Strong analytical and problem‑solving abilities.
• Excellent documentation and communication skills.
• Ability to work effectively with customers, auditors, suppliers and cross‑functional teams.
• High attention to detail and commitment to engineering rigour.
• Proactive mindset with the ability to lead optimisation and improvement initiatives.
• This role will require some ad-hoc international travel.

If this sounds like the position for you, we'd love to hear from you! Please forward your details on to Info@fauntrackway.co.uk