Mechanical Design Engineer

Syos Aerospace; Fareham; Hybrid; GBP 60,000 - 80,000; Full time

Job summary

SYOS Aerospace is seeking a Mechanical Design Engineer – UAS to lead validation, adaptation and engineering change activities for our large-scale unmanned air systems in the UK. You will ensure drawings, structural designs and manufacturing data meet UK aviation and defence requirements, working with our New Zealand design team.

This hands-on role covers airframe structures, propulsion integration and design modifications for systems weighing 200 kg+.

Qualifications

• Bachelors or Masters in Mechanical or Aerospace Engineering.
• Experience in mechanical design of large-scale airframes and heavy unmanned systems.
• Knowledge of aerospace drawings and BS 8888 standards.
• Proficient with 3D CAD tools such as CATIA V5 or NX.
• Awareness of UK MAA, DAOS and CAA S2 regulatory requirements.
• Experience collaborating with international engineering teams.
• Understanding of structural integrity, load-bearing design and lightweight methods.
• Ability to assess design changes balancing performance, safety and manufacturability.
• Familiarity with safety management systems like Def Stan 00-56.
• Strong problem-solving and communication skills.

Responsibilities

• Lead mechanical design validation for UK production and regulatory compliance.
• Provide technical design authority for changes and ECOs.
• Ensure airframe integrity and alignment with DAOS/CAA requirements.
• Maintain engineering master data and document version control.
• Collaborate with production, workshop technicians and procurement.
• Investigate issues and implement corrective actions to improve safety and reliability.
• Support design assurance and safety verification with CVE.

Skills

Mechanical design

Aerospace engineering

3D CAD

CATIA V5 / NX

Configuration management

Education

ME/AE degree

Tools

CATIA V5

Siemens NX

Job description

Build the Future of Autonomous Systems

SYOS designs and manufactures advanced uncrewed systems across air, land, sea, and subsurface domains. We combine intelligent engineering, AI-driven autonomy, and innovative design to create next-generation vehicles operating in some of the world's most challenging environments.

About the Role

We’re looking for an experienced Mechanical Design Engineer – UAS to lead mechanical design validation, adaptation and engineering change activities for SYOS’s large-scale Uncrewed Air Systems in the UK.

Working closely with the Air Vehicle Design Lead and our core design team in New Zealand, you’ll help translate and adapt established designs for UK production, ensuring engineering drawings, structural designs and manufacturing data meet applicable UK aviation and defence requirements.

This is a hands‑on technical specialist role focused on platforms weighing 200 kg and above. You’ll provide mechanical design expertise across airframe structures, load‑bearing components, propulsion integration and engineering modifications, helping ensure our systems meet demanding performance, safety and compliance standards.

You’ll also collaborate with production teams, workshop technicians, manufacturing partners and procurement to resolve design challenges and ensure engineering solutions can be manufactured, assembled and tested effectively.

Key Responsibilities

• Lead mechanical design validation: Review and validate mechanical drawings, material specifications, structural designs and manufacturing data produced by the New Zealand engineering team, ensuring suitability for UK production and applicable regulatory requirements.
• Provide technical design authority: Evaluate and implement safe engineering changes, repairs and design modifications, resolving manufacturing concessions and identifying when changes to the Certificate of Design (CofD) are required.
• Ensure structural integrity and compliance: Support airframe integrity, structural and strength assessments, and alignment with relevant CAA and MAA requirements, including the DAOS framework and applicable design standards.
• Manage engineering configuration: Maintain local engineering master data, technical files, Engineering Change Orders (ECOs) and document version control to ensure accurate, traceable and auditable design histories.
• Collaborate with production and procurement: Work closely with workshop technicians, manufacturing partners and procurement teams to resolve design‑for‑manufacture challenges and support efficient physical builds.
• Investigate technical issues: Analyse mechanical failures and production issues, identify potential design flaws and develop appropriate corrective actions to improve safety, reliability and performance.
• Support design assurance and safety: Work with the Air Vehicle Design Lead and Compliance Verification Engineer (CVE) to support design verification, safety management and compliance with applicable certification requirements.

What We’re Looking For

• A Bachelor's or Master's degree, or equivalent qualification, in Mechanical Engineering, Aerospace Engineering or a related technical discipline.
• Proven experience in mechanical design of large-scale airframes, propulsion integration or heavy‑payload unmanned systems weighing 200 kg or more.
• Strong understanding of aerospace engineering drawings, configuration management and drafting standards, such as BS 8888.
• Experience interrogating complex 3D CAD models, ideally using CATIA V5, Siemens NX or similar engineering design software.
• Awareness of UK Military Aviation Authority (MAA) regulations, Design Approved Organisation Scheme (DAOS) requirements and CAA Specific Category S2 operational approvals.
• Experience working with international engineering teams and validating designs against local regulatory and technical requirements.
• Understanding of structural integrity, load‑bearing structures, lightweight design and engineering modifications for demanding aerospace applications.
• The ability to assess design changes methodically, balancing structural performance, safety, manufacturability and compliance.
• Familiarity with safety management systems, including Def Stan 00-56, or the ability to contribute to their development and implementation.
• Strong problem‑solving and troubleshooting skills, with excellent written and verbal communication.
• The ability to explain complex design and compliance requirements clearly to production teams and other stakeholders.

Why SYOS

Our mission is to extend human capability, protect people, and deliver operational advantage through accessible, scalable, and intelligent autonomous technology.

Join a team of engineers, builders, and innovators pushing boundaries and solving real‑world challenges across robotics, aerospace, and autonomy.

If you’re ready to apply your mechanical design expertise to complex aerospace systems and help shape the next generation of autonomous aircraft, we’d love to hear from you.