Principal Mechanical Design Engineer

IO Associates; Nuneaton; On-site; GBP 65,000 - 90,000; Full time

Job summary

IO Associates is seeking an experienced Principal Mechanical Design Engineer to join a high-performing automotive engineering team in the Nuneaton area. You will lead complex mechanical design activities across the product lifecycle and mentor junior engineers while collaborating with systems, electronics, software, manufacturing, quality and programme management.

The role emphasizes leading design concepts, performing advanced CAD modelling, GD&T, FEA validation, and DFMEA activities to ensure

Qualifications

• Bachelor's Degree in Mechanical Engineering or related field.
• 8+ years in automotive mechanical product development.
• Strong SolidWorks CAD proficiency.
• Excellent understanding of Geometric Dimensioning and Tolerancing (GD&T).
• Experience using SolidWorks Simulation or Ansys.

Responsibilities

• Lead the mechanical design and development of complex automotive components from concept through production.
• Create robust 3D CAD models and manufacturing drawings using SolidWorks and GD&T.
• Perform engineering calculations including tolerance stack, fit calculations, and thermal assessments.
• Conduct FEA using SolidWorks Simulation and/or Ansys to validate designs.
• Support DFMEA activities and Design for Manufacturing reviews.
• Mentor junior engineers and promote engineering standards and best practices.
• Manage engineering activities to deliver projects on time and to quality standards.

Skills

SolidWorks

GD&T

FMEA

Project management

Mentoring

Education

Bachelor's in Mechanical Engineering

Tools

SolidWorks Simulation

Ansys

Job description

Nuneaton

Principal Mechanical Design Engineer

Posted on Thursday, 1st October 2026

Job Description – Principal Mechanical Engineer

Overview

We are seeking an experienced Principal Mechanical Engineer to join a high-performing engineering team developing advanced electromechanical products for the automotive sector. This is a senior technical position responsible for leading complex mechanical design activities throughout the product development lifecycle.

The successful candidate will be an experienced and self‑motivated engineer capable of independently solving challenging engineering problems while collaborating with multidisciplinary teams including systems, electronics, software, manufacturing, quality, and programme management. This role also provides technical leadership and mentoring to other engineers, promoting engineering excellence and best practice.

Key Responsibilities

• Lead the mechanical design and development of complex automotive components and assemblies from concept through production.
• Create robust 3D CAD models and manufacturing drawings using SolidWorks, applying advanced GD&T principles.
• Perform engineering calculations including:
  • Tolerance stack analysis
  • Press and interference fit calculations
  • Thermal expansion (CTE) assessments
  • O-ring and sealing calculations
  • Basic stress and structural approximations
• Conduct finite element analysis (FEA) using SolidWorks Simulation and/or Ansys to validate designs against functional load cases.
• Support Design for Manufacturing (DFM) reviews with suppliers and manufacturing teams.
• Participate in Design Failure Mode and Effects Analysis (DFMEA) activities.
• Support structured problem-solving activities using 8D or equivalent methodologies.
• Present design concepts, technical analyses, and engineering recommendations to internal stakeholders, suppliers, and customers.
• Collaborate effectively within cross-functional engineering teams while maintaining ownership of individual workstreams.
• Mentor junior engineers and contribute to continuous improvement of engineering standards, processes, and best practices.
• Manage assigned engineering activities, ensuring projects are delivered on schedule and to the required quality standards.

Essential Qualifications

• Bachelor's Degree in Mechanical Engineering or a related engineering discipline.
• Minimum of 8 years' experience in mechanical product development within the automotive or comparable engineering sector.
• Strong proficiency with SolidWorks CAD.
• Excellent understanding and application of Geometric Dimensioning and Tolerancing (GD&T).
• Experience using structural simulation software such as SolidWorks Simulation or Ansys.
• Ability to perform detailed engineering calculations supporting mechanical design decisions.
• Experience conducting DFMEA.
• Knowledge of structured root cause analysis methodologies such as 8D.
• Demonstrated project planning and workload management skills.
• Strong communication and stakeholder management skills, including customer and supplier interaction.
• Ability to work independently while contributing effectively within multidisciplinary teams.

Desirable Skills & Experience

• Experience designing automotive actuator, suspension, or motion control systems.
• Knowledge of hydraulic and electromechanical system design.
• Familiarity with Design Verification Plan and Report (DVP&R) processes.
• Advanced experience using Ansys Mechanical.
• MATLAB or scripting experience for engineering calculations and automation.
• Master's Degree in Mechanical Engineering or a related discipline.
• Practical hands‑on engineering experience gained through laboratory, workshop, or prototype development activities.

What We're Looking For

The ideal candidate is an experienced mechanical engineer who combines strong technical capability with practical problem‑solving skills and a collaborative approach. They will be comfortable taking ownership of challenging engineering problems, influencing design decisions, mentoring colleagues, and delivering high‑quality engineering solutions within a fast‑paced product development environment.