Mechanical Design Engineer

Skyfly Technologies Ltd; Banbury; On-site; GBP 55,000 - 75,000; Full time

Job summary

Skyfly Technologies Ltd designs, builds, and sells eVTOL aircraft for defence and commercial markets. You will design mechanical structures, enclosures, and assemblies for UAV and AXE platforms, delivering robust, lightweight, and manufacturable solutions while balancing aerodynamics, safety, and certification requirements.

The role requires hands-on CAD, surfacing, and analysis, plus collaboration with electrical, systems, and manufacturing teams to ensure aircraft systems are safe and

Qualifications

• Degree in Mechanical/ Aerospace Engineering or related field.
• Several years of mechanical design experience in aerospace/defence/automotive.
• Experience taking designs from concept to production is a strong advantage.
• Security clearance or eligibility to obtain is desirable.

Responsibilities

• Design mechanical structures, enclosures, mounting systems, and assemblies for UAV/drone and AXE platforms.
• Develop Class-A and aerodynamic surfaces balancing aesthetics, aerodynamics and manufacturability.
• Produce detailed 3D CAD models, assemblies, and drawings using NX and other CAD tools.
• Perform structural, thermal, and vibration analyses to validate designs against aerospace requirements.
• Select materials and manufacturing processes for lightweight, high-reliability aerospace apps.
• Support integration with airframe, electrical, and avionics systems across product lines.
• Develop and execute test plans for prototype components and assemblies.
• Ensure designs align with aerospace and defence standards and certification processes.
• Prepare design reports and documentation for internal gates and regulatory submissions.
• Collaborate with supply chain and manufacturing for cost-effective production-ready designs.
• Lead design iterations and root-cause investigations in response to test results.

Skills

Siemens NX

3D CAD

FEA

Aerodynamic surfacing

Mechanical design

Education

Degree in Mechanical or Aerospace Engineering

Tools

SolidWorks

CATIA

Realize Shape / NX Realize Shape

Job description

Skyfly Technologies Ltd designs, builds, and sells electric vertical take-off and landing (eVTOL) aircraft for the general aviation and defense markets. The company focuses on innovative, sustainable air mobility solutions that push the boundaries of current aviation technology. Team members collaborate across disciplines to develop safe, efficient, and high-performance aircraft. Working at Skyfly Technologies Ltd offers the opportunity to contribute to cutting-edge aerospace projects with real-world impact. The company values technical excellence, creativity, and a strong commitment to quality and safety.

Role Summary

The Mechanical Design Engineer is responsible for the mechanical design, integration, and packaging of structures, enclosures, and components across Skyfly Technologies' product range, spanning both defence and the AXE commercial aircraft programmes. The role holder will design robust, lightweight, and manufacturable mechanical solutions — including structural, aerodynamic, and enclosure surfaces — that meet demanding aerospace performance, safety, and certification requirements.

• This is a hands-on engineering role combining CAD design, surfacing, analysis, and prototyping with close collaboration across electrical, systems, and manufacturing teams. The successful candidate will play a central role in ensuring Skyfly's aircraft systems are safe, efficient, and ready for both defence and commercial aviation applications.

Key Responsibilities

• Design mechanical structures, enclosures, mounting systems, structural interfaces, and component assemblies used across UAV/drone and AXE commercial aircraft platforms
• Develop high-quality Class-A and aerodynamic surfacing for exterior panels, fairings, cowlings, and enclosures, balancing aesthetics, aerodynamics, and manufacturability
• Produce detailed 3D CAD models, assemblies, and drawings using Siemens NX and other industry-standard design software
• Conduct structural, thermal, and vibration analysis (FEA) to validate designs against aerospace and defence requirements
• Select materials and manufacturing processes appropriate for lightweight, high-reliability aerospace applications
• Support integration of mechanical designs with airframe, electrical, and avionics systems across both product lines
• Develop and execute test plans for prototype components and assemblies, including mechanical, thermal, and structural testing
• Ensure designs align with relevant aerospace and defence design and certification standards
• Prepare technical documentation, design reports, and reviews to support internal gates and regulatory submissions
• Support root cause investigation and design iteration in response to test results or field issues
• Work closely with supply chain and manufacturing to ensure designs are cost-effective and production-ready
• Strong mechanical design skills with proficiency in 3D CAD; strong hands-on experience in Siemens NX is essential, with SolidWorks, CATIA, or equivalent an advantage
• Demonstrable surfacing skills — confident creating and refining Class-A or aerodynamic freeform surfaces (e.g. NX Realize Shape or equivalent) for exterior and aesthetic components
• Practical understanding of structural and enclosure design, including component integration and packaging
• Working knowledge of FEA tools and their application to structural and thermal analysis
• Understanding of lightweight materials and manufacturing methods relevant to aerospace (composites, sheet metal, additive manufacturing)
• Familiarity with relevant safety and certification standards for aerospace or defence applications
• Ability to work across multiple concurrent programmes and balance competing priorities
• Strong problem-solving skills with a methodical, analytical approach to design and testing
• Effective communicator, able to work collaboratively across electrical, systems, and manufacturing disciplines
• Comfortable operating in a fast-paced, early-stage business environment with significant autonomy
• Organised approach to documentation, version control, and design change management

Experience & Qualifications

• Degree in Mechanical Engineering, Aerospace Engineering, or a related discipline
• Several years' experience in mechanical design engineering, ideally within aerospace, defence, or automotive sectors
• Demonstrable experience designing structural components, enclosures, or surfaced/aesthetic parts
• Experience taking designs from concept through prototype, test, and into production is a strong advantage
• Familiarity with aerospace or defence design and certification processes is desirable but not essential
• Security clearance (existing or willingness and eligibility to obtain, given exposure to defence programmes)

Reporting & Team Responsibilities

• Reports to the Engineering Lead / Head of Engineering
• Works closely with electrical, systems, and manufacturing engineering teams
• Collaborates across both the defence UAV/drone team and the AXE commercial aircraft programme
• Liaises with suppliers and manufacturing partners on design for manufacture and assembly
• Contributes to design reviews and technical governance across Skyfly's engineering programmes