Prototype Design and Integration Engineer

Airbus; Getafe; On-site; EUR 60,000 - 85,000; Full time

Job summary

Airbus Helicopters España, SA is seeking a Prototype Design and Integration Engineer to join the Getafe site in Madrid. You will lead the preliminary design of mechanical, structural, and electrical aspects for experimental UAS prototypes and define ICDs for sensors, power, and data interconnects.

You will integrate systems across diverse flight test assets and collaborate with airworthiness teams. The role emphasizes rapid prototyping, fabrication, and verification, with a focus on

Qualifications

• Education in aerospace/mechanical disciplines with emphasis on design and integration.
• Experience in aerospace mechanical design, integration of physical systems, or rapid prototyping.
• Experience with ICDs and airborne equipment integration.

Responsibilities

• Lead preliminary mechanical, structural, and electrical design for experimental UAS prototypes.
• Define and manage Interface Control Documents (ICDs) for sensors and payloads.
• Conduct platform integration studies for diverse flight test assets.
• Leverage rapid manufacturing techniques including 3D printing and CNC fabrication.
• Oversee ground integration, fit-checks, and risk reduction prior to flight trials.
• Coordinate with airworthiness specialists to establish permit-to-fly criteria.
• Balance SWaP-C constraints across prototype variants.

Skills

Prototype design

System integration

ICD development

Rapid prototyping

Airworthiness concepts

Mass properties awareness

Multi-disciplinary coordination

Education

Degree/Master in Aerospace, Mechanical, Mechatronics, or Systems Engineering

Tools

CATIA V5/3DX

SolidWorks

Job description

Job Description:
Airbus Helicopters is looking for a Prototype Design and Integration Engineer (f/m) based in Getafe (Madrid metropolitan area). We are looking for passionate individuals to join a cross-divisional project that will shape the future of autonomous flight for UAS (Uncrewed Aerial Systems) and enable 24/7 mission capabilities in the most challenging operational conditions.
The position is functionally attached to the Head of Engineering Spain and reports operationally to the Research and Innovation Leader in Spain..

Your working environment:
You will be based in Getafe, Airbus’s third-largest site globally where all three divisions converge. Madrid offers an unparalleled lifestyle for those looking to balance a high-impact career with a vibrant cultural scene. You will collaborate closely with various Engineering departments within Airbus Helicopters and the Helicopter Programs.

Your challenges:

• Preliminary Prototype & Modification Design: Lead the preliminary mechanical, structural, and electrical design for experimental UAS prototypes, specialized mounting provisions, and modular airborne payload enclosures.
• Multi-System Interface Definition: Define, document, and manage Interface Control Documents (ICDs)-encompassing mechanical attachments, electrical power distribution, thermal dissipation, and high-speed data interconnects-between novel sensors (cameras, LiDAR, radar), AI processing units, and flight test platforms.
• Platform Integration Studies: Conduct preliminary engineering studies to adapt and integrate experimental mission systems into diverse flight test assets (uncrewed platforms and crewed aircraft), ensuring structural integrity, mass balance, and minimal aeromechanical impact.
• Rapid Prototyping & Fabrication: Accelerate iteration cycles by leveraging rapid manufacturing techniques, additive manufacturing (3D printing), precision CNC fabrication, and custom wire harness integration.
• Ground Integration & Functional Verification: Supervise physical fit-checks, mechanical installation, electrical bench integration, and thermal/EMI risk reduction prior to experimental flight trials.
• Airworthiness & Design Office Alignment: Coordinate closely with structural, system safety, and airworthiness specialists to establish permit-to-fly documentation and safe-for-flight release criteria for experimental trial modifications.
• Trade-Offs & SWaP-C Optimization: Reconcile payload operational requirements with airframe physical boundaries, actively optimizing Size, Weight, Power, and Cooling (SWaP-C) constraints across prototype variants.

Your profile:

• Education: Degree or Master’s in Aerospace, Mechanical, Mechatronics, or Systems Engineering. Specialization in Aerospace Vehicle Design or Mechatronic Prototyping is highly valued.
• Professional Experience: At least 5 years of professional experience in aerospace mechanical design, physical systems integration, or rapid prototyping within an aerospace OEM, flight test unit, or agile robotics company.
• Physical & Electrical Systems Integration: Proven track record of developing multi-disciplinary ICDs and integrating complex airborne equipment (electro-optical payloads, computing modules, power distribution units).
• CAD & Preliminary Design Mastery: Proficiency in 3D CAD platforms (e.g., CATIA V5/3DX, SolidWorks) for preliminary structural packaging, bracketry, aerodynamic fairings, and structural assemblies.
• Aeromechanical & Mass Properties Awareness: Understanding of aircraft weight and balance (CG envelope), structural load paths, thermal dissipation, and basic aerodynamic considerations for external stores or modifications.
• Hands-on Prototyping Skills: Practical experience with additive manufacturing (3D printing), rapid shop tooling, and aerospace harness assembly practices.
• Airworthiness & Modification Standards: Familiarity with aerospace modification design principles, environmental qualification guidelines (DO-160), and experimental flight permit processes (EASA/national authorities).
• Systems Thinking & Pragmatic Mindset: Ability to translate loose operational concepts into robust physical solutions, demonstrating agility and decisive technical judgment in fast-paced R&D environments.
• Language: Fluent English (C1 minimum) and Spanish.
• Travel: Availability to travel sporadically at a national and European level in line with flight testing plans.

This job requires an awareness of any potential compliance risks and a commitment to act with integrity, as the foundation for the Company’s success, reputation and sustainable growth.
Company:
Airbus Helicopters España, SA
Employment Type:
Permanent
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Experience Level:
Professional
Job Family:
Chief Engineering & Architecture
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