Aircraft Design Engineer / Mechanical Design Engineer

Hill Helicopters; Stafford; On-site; GBP 45,000 - 75,000; Full time

Job summary

Hill Helicopters is seeking an Aircraft Design Engineer to play a crucial role in designing next-generation light helicopters. The ideal candidate will contribute to innovative mechanical systems while collaborating within a dynamic team environment. This position offers rare insight across the full aircraft lifecycle, from concept to certification, in an exciting project that shapes the future of UK rotorcraft design.

Benefits

Access to modern design tools

On-site test facilities

Dynamic team culture

Competitive salary and benefits

Qualifications

• Experience with light aircraft systems and relevant manufacturing processes.
• Good understanding of GD&T, tolerance analysis, and drawing standards.
• Knowledge of aerospace certification requirements is advantageous.

Responsibilities

• Design aircraft structures and mechanical systems for a new helicopter platform.
• Generate 3D models and engineering drawings using PTC Creo.
• Collaborate with teams to ensure fit, function, and integration.

Skills

Analytical skills

Communication

Team collaboration

Education

Degree in Aerospace Engineering

Degree in Mechanical Engineering

Tools

PTC Creo

Job description

About the Role:

This is aonce-in-a-lifetime opportunityto play a key role in the design and development of a family ofnext-generation light helicopters. As anAircraft Design Engineer / Mechanical Design Engineer, you will join a high-performing team within aUK-based helicopter OEM, contributing directly to the creation of a clean-sheet civil rotorcraft platform.

You will be responsible for mechanical and structural design across multiple aircraft systems, usingPTC Creo to generate detailed 3D models, assemblies, and drawings. The role spans from concept development through to detailed design, integration, and certification support—offering rare visibility across the full aircraft lifecycle.

Key Responsibilities:

• Design aircraft structures, mechanical systems, and components for a new light helicopter platform.


• Generate 3D models, assemblies, and engineering drawings usingPTC Creo.


• Perform engineering calculations and analysis to support design creation and validate mechanical solutions.


• Collaborate with airframe, propulsion, systems, and manufacturing teams to ensure fit, function, and integration of mechanical designs.


• Participate in concept development, trade studies, and weight and cost optimisation activities.


• Create and maintain design documentation, including interface control documents, BOMs, and configuration data.


• Support structural analysis teams by preparing and refining geometry for simulation.


• Liaise with suppliers and manufacturing partners to ensure designs meet production and assembly requirements.


• Contribute to design reviews, safety assessments, and certification documentation.

Requirements:

Essential:

• Degree in Aerospace Engineering, Mechanical Engineering, or a related discipline.


• Strong knowledge oflight aircraft systemsand relevantmanufacturing processes.


• Exceptional knowledge of engineering fundamentals, including materials, mechanics, and structural principles.


• Proficiency withPTC Creofor 3D modelling and drafting.


• Strong analytical skills with the ability to perform engineering calculations and analyses to support design decisions.


• Working knowledge of design for manufacture and assembly (DFMA) in an aerospace context.


• Good understanding of GD&T, tolerance analysis, and drawing standards (e.g. BS8888 or ASME Y14.5).


• Strong desire to design, test, refine, and achieve approval of your designs.


• Self-motivated, confident, and a team player with excellent communication skills.


• Supportive and cooperative personality, crucial for thriving within a close-knit, world-class team.

Desirable:

• Experience working on rotorcraft or light aircraft platforms.


• Passion for light aircraft and enthusiasm for creating new products.


• Knowledge of aerospace certification requirements (e.g. CS-27 or FAR Part 27).


• Familiarity with PLM systems and configuration control (e.g. Windchill, Teamcenter).


• Hands-on experience with prototype or low-rate production environments.

What We Offer:

• A unique chance to help shape the future of UK rotorcraft design through a credible new aircraft programme.


• Involvement in a clean-sheet, full-aircraft development with visibility across design, integration, and certification.


• A dynamic and supportive team culture with rapid decision-making and strong engineering influence.


• Access to modern design tools, on-site test facilities, and highly skilled cross-functional teams.


• Competitive salary and benefits.