Mechnical Design Engineer

Aalto; Farnborough; On-site; GBP 42,000 - 64,000; Full time

Benefits offered by this job

Performance Bonus

25 days annual leave

Private Healthcare

Pension Contributions

Income Protection & Life Assurance

Electric Vehicle & Car Scheme

Employee Assistance Programme

Employee Discounts

Job summary

AALTO in Farnborough is seeking a Mechanical Design Engineer to contribute to the design, development, and delivery of mechanical systems for Zephyr and future high-altitude aircraft platforms.

You will work in a multidisciplinary team, developing solutions across concept to manufacture, testing, and support, building expertise in lightweight aerospace structures and advanced design practices.

Qualifications

• Degree, HND, or equivalent in Mechanical Engineering, Aerospace Engineering, or related field.
• Typically 2–5 years' experience in aerospace, defence, or another highly regulated engineering industry.
• Experience using professional 3D CAD software, with SolidWorks experience highly advantageous.
• Strong capability in producing engineering drawings, models, and technical documentation.
• Understanding of product lifecycle management processes and manufacturing considerations.

Responsibilities

• Support development of concept and detailed mechanical design solutions meeting product and system requirements.
• Create 3D CAD models, assemblies, and drawings using SolidWorks or equivalent.
• Generate and maintain product definition data within PDM/PLM systems.
• Deliver design activities in line with schedules, processes, and airworthiness standards.
• Support design reviews with analyses, presentations, and technical reporting.
• Provide engineering support to manufacturing to resolve production issues.
• Plan and execute mechanical testing and qualification programmes.
• Collaborate with manufacturing, procurement, integration, and test teams for manufacturability.

Skills

Mechanical design

Aerospace engineering

Multidisciplinary collaboration

Analytical problem solving

Communication

Project management

Education

Bachelor's degree in Mechanical Engineering

Tools

SolidWorks

PDM/PLM systems

Job description

AALTO, a global leader in Stratospace. Based in Farnborough, AALTO is an Airbus subsidiary that manufactures, operates, and delivers services with its solar-powered, stratospheric platform: Zephyr.

Zephyr’s persistence enables continuous flight for months at a time. Its current flight-time record of over 67 days in the stratosphere. From above 60,000+ft, or 20km above ground, AALTO can deliver several applications including direct-to-device connectivity and high-resolution Earth observation.

AALTO operates in a new operational layer between most of air traffic and low-Earth orbit, Stratospace. This is where high-altitude platforms led by Zephyr deliver services to commercial and government partners. We can help monitor environments, observe borders, track natural disasters and connect unconnected communities.

Join us as we create a new domain of aerospace: Stratospace. You’ll be part of a highly-skilled, innovative and passionate group of people – Team AALTO. Together, we can Unlock Stratospace.

About The Role

Join AALTO's innovative engineering team as a Mechanical Design Engineer, contributing to the design, development, and delivery of mechanical systems for Zephyr and future high-altitude aircraft platforms.

Working within a multidisciplinary engineering environment, you will develop mechanical design solutions that support the full product lifecycle, from concept development and detailed design through to manufacture, integration, testing, and operational support. This is an excellent opportunity to build expertise in advanced aerospace technologies, lightweight composite structures, and cutting-edge aircraft design while working alongside experienced engineers and technical specialists.

The role offers significant opportunities for professional growth, allowing you to progressively take ownership of more complex engineering challenges as your technical expertise develops.

Responsibilities to include:

• Support the development of concept and detailed mechanical design solutions that meet product and system requirements.
• Create 3D CAD models, assemblies, and engineering drawings using SolidWorks or equivalent CAD software.
• Generate and maintain product definition data within PDM and PLM systems.
• Deliver allocated design activities in line with project schedules, engineering processes, and airworthiness standards.
• Support design reviews through the preparation of engineering analyses, presentations, technical reports, and supporting evidence.
• Provide engineering support to manufacturing activities, helping resolve production and assembly-related issues.
• Assist with the planning, coordination, and execution of mechanical testing and qualification programmes.
• Collaborate with manufacturing, procurement, integration, and test teams to ensure practical and manufacturable design solutions.
• Implement engineering changes in accordance with configuration management and change control processes.
• Contribute to continuous improvement initiatives that enhance quality, efficiency, manufacturability, and cost performance.
• Support root cause investigations and failure analysis activities associated with design, manufacturing, or operational issues.
• Develop knowledge and expertise in composite structures, aerospace engineering practices, and Design Organisation processes.
• Effectively manage assigned work packages, communicating progress, risks, and issues to technical leads and managers.

Skills and Knowledge Required

• Degree, HND, or equivalent qualification in Mechanical Engineering, Aerospace Engineering, or a related engineering discipline.
• Typically 2-5 years' experience within aerospace, defence, or another highly regulated engineering industry.
• Experience using professional 3D CAD software, with SolidWorks experience highly advantageous.
• Strong capability in producing engineering drawings, models, and technical documentation.
• Understanding of engineering design methodologies and product lifecycle management processes.
• Experience working with PDM and PLM systems.
• Ability to interpret technical requirements and develop practical engineering solutions.
• Understanding of manufacturing processes and design for manufacture principles.
• Strong analytical and problem-solving skills.
• Excellent communication and collaboration abilities within multidisciplinary teams.
• Ability to manage multiple priorities while delivering work to agreed deadlines.
• A proactive approach to continuous improvement and professional development.

In addition to a competitive, market-aligned salary, we offer a comprehensive benefits package designed to support your wellbeing, financial security, and work-life balance:

Performance Bonus
Benefit from our short-term incentive plan, recognising and rewarding individual and company success.

Generous Annual Leave
Enjoy 25 days of annual leave, giving you the time to rest, recharge, and spend time on what matters most.

Private Healthcare
Access private medical insurance, alongside dental and optical cashback schemes, helping you and your family stay healthy.

Pension Contributions
Plan confidently for the future with our competitive personal pension scheme.

Income Protection & Life Assurance
Gain added peace of mind through income protection and life assurance cover, providing support when you need it most.

Electric Vehicle & Car Scheme
Access our salary sacrifice vehicle scheme, offering a cost-effective way to drive the latest cars.

Employee Assistance Programme
Receive confidential professional support whenever you need it through our dedicated employee assistance programme.

Employee Discounts
Enjoy a wide range of discounts and offers through Perkbox, covering everything from shopping and travel to leisure activities and everyday essentials.

This is all part of our commitment to creating an environment where our people can thrive both professionally and personally.

If this role isn’t quite what you’re looking for but are keen to be contacted about opportunities at AALTO, you can register your details here: https://careers.aaltohaps.com/connect