Principal Mechanical Design Engineer

Ultra Cyber Limited; England; On-site; GBP 75,000 - 110,000; Full time

Job summary

Cyber Business seeks a Principal Mechanical Engineer to lead mechanical design from concept to production for secure products. You will validate requirements, document analyses and develop robust solutions using CAD tools and engineering workflows.

This role emphasizes defence standards, TEMPEST and EMC compliance, and close collaboration with production. You will drive 3D CAD modelling, drafting, and analysis, including stress, thermal and FEA/CFD methods, while guiding BOM management in PLM

Qualifications

• Degree in Mechanical Engineering or closely related discipline.
• Strong understanding of materials science, mechanics, stress and thermal analysis.
• Experience designing rugged electronic enclosures for defence.
• Extensive 3D CAD modelling and drafting, Creo preferred.
• Experience with stress and thermal analysis using hand calculations, FEA and CFD.
• Experience with PLM systems, Windchill preferred, and BOM management.
• Ability to multi-task and deliver under pressure.
• Ability to produce precise engineering drawings to BS8888.

Responsibilities

• Define and manage mechanical design requirements, ensuring validation and verification.
• Develop and deliver robust mechanical solutions using CAD and engineering toolsets.
• Create and peer review artefacts including drawings, design data packs, analysis reports, plans and procedures.
• Define, analyse and document predicted mechanical behaviours and performance.
• Optimize design for machined, injection moulded, extrusion, sheet metal and casting parts.
• Perform tolerance analysis of close tolerance parts and complex assemblies.
• Produce mechanical designs for systems meeting MIL–STD and DEF–STAN, EMC and TEMPEST requirements.
• Create and review high–quality drawings to BS8888 standard.
• Select optimum engineering materials and finishes for cost and performance.
• Design production jigs and fixtures with production engineers.
• 3D Print and scan components; produce rapid prototypes.
• Develop mechanical test solutions and procedures to verify product.
• Liaise with production and supply chain to transition to manufacture.

Skills

3D CAD modelling

Stress analysis

Thermal analysis

Vibration analysis

Materials science

Manufacturing processes

Assembly techniques

Engineering mechanics

Heat transfer

Defense industry experience

Education

Degree in Mechanical Engineering or related discipline

Tools

Creo CAD v7+

Windchill PLM

PLM/BOM management tools

ERP interfacing

Job description

Cyber Business

Our Cyber business unit is at the forefront of pioneering advanced cryptographic and key management solutions, facilitating the confidential exchange of vital information for customers operating at both tactical and strategic echelons. Join our team and participate in the innovation that ensures the highest security and trust worldwide.

Job Description

As a Principal Mechanical Engineer, you will provide technical expertise across the design, development, testing and qualification of mechanical assemblies for advanced security critical products. You will lead mechanical engineering activities from concept through to production, ensuring designs meet functional, environmental and regulatory requirements.

Key Responsibilities

• Define and manage mechanical design requirements, ensuring validation and verification.
• Responsible for developing, documenting and delivering robust mechanical solutions for complex systems using the 3D CAD system and the company engineering toolsets.
• Create and peer review technical artefacts, including mechanical design documentation, design data packs, analysis reports, plans and procedures in accordance with our product development framework.
• Define, analyse and document predicted mechanical functional behaviours and performance.
• Optimize the design of parts based on various manufacturing technologies: machined from solid, injection moulding, extrusion, sheet metal and casting.
• Perform tolerance analysis of close tolerance parts and complex assemblies.
• Produce mechanical designs for complex systems that meet defence standards MIL–STD and DEF–STAN, EMC and TEMPEST requirements and harsh environmental conditions.
• Create and review high–quality drawings to BS8888 standard to guarantee design precision.
• Select optimum engineering materials and finishes to suit cost and performance.
• Design production jigs and fixtures in conjunction with production engineers.
• 3D Print and scan components; and produce rapid prototypes.
• Responsible for mechanical test solution and development of test procedures to support the verification of the product.
• Liaise with the production and supply chain teams to ensure a seamless transition to manufacture.

Essential Skills, Qualification and Experience

• Degree in Mechanical Engineering or closely related discipline.
• Profound understanding of key mechanical engineering principles e.g. materials science and selection, engineering mechanics, stress analysis, vibration analysis, thermodynamics, heat transfer, assembly techniques and manufacturing processes.
• Seasoned experience in hands–on design of complex and rugged electronic enclosures for the defence industry.
• Extensive experience of 3D CAD modelling and drafting. Creo CAD version 7 or later is preferable.
• Deep technical expertise of undertaking stress and thermal analysis using hand calculations, FEA and CFD.
• Long term experience of using PLM systems, preferably Windchill.
• Proven track record managing BOMs on PLM systems and interfacing with ERP systems.
• Proven ability to multi–task, prioritise workload, and work under pressure to deliver on multiple projects simultaneously.
• Meticulous in drafting and reviewing complex engineering drawings to guarantee design precision.