Senior Design Engineer

Job Description

Job Title: Senior Design Engineer

Department: New Product Development (NPD)

Reports To: Head of Design / Design Manager

Location: Lancashire - Onsite Role

Position Purpose

A market leading lighting manufacturer is seeking an experienced and highly skilled Senior Design Engineer to join their innovative NPD team. This role is instrumental in the end-to-end development of cutting-edge, sustainable lighting products - from initial concept to full production. The successful candidate will possess a strong foundation in mechanical or product design, a keen eye for detail, and a passion for delivering exceptional and commercially viable solutions.

Key Responsibilities

• Lead the delivery of complex, large-scale projects in strict accordance with the NPD Gate process.
• Design and develop products that meet all project specifications, timelines, and quality standards.
• Demonstrate a thorough understanding of project requirements and communicate design rationale clearly, challenging and refining specifications where appropriate.
• Deliver safe, reliable, and commercially successful design solutions using tools such as FMEA.
• Accurately complete all required documentation to support design outputs.
• Utilize a range of design tools including sketches, models, prototypes, and 3D CAD to effectively communicate ideas.
• Create precise CAD and PLM data in line with best practice standards.
• Develop accurate, costed Bills of Materials (BoMs) for all new designs.
• Investigate and address cost variances, proposing solutions and communicating with key stakeholders.
• Produce production-ready components and assemblies, integrating insights from research into product technologies and structures.
• Continuously improve existing products and processes, identifying opportunities for innovation and efficiency.
• Enhance installation methodologies by developing intuitive, safe, and user-friendly solutions supported by physical samples and clear instructions.
• Apply root cause analysis to resolve design issues, implementing robust corrective actions.
• Mentor and support Trainee Design Engineers and Apprentices, fostering their technical and professional growth.
• Stay informed on industry developments, trends, and competitor activity to ensure the business remains ahead of the curve.

Essential Skills & Qualifications

• Degree or equivalent qualification in Mechanical or Product Design.
• 5+ years of industry experience with a track record of successfully delivering complex projects on time, within specification and budget.
• Proficient in designing tooled components (plastic moulding, die-casting, extruded profiles in plastic and aluminium).
• Experienced in light gauge sheet metal design and fabrication.
• Strong 3D CAD skills (ideally Solid Edge), with the ability to produce detailed drawings and tolerance stacks for both mechanical and electrical assemblies.
• Confident in using Microsoft Office Suite and other relevant software tools.
• Skilled in creating prototypes (handmade, sketch, CAD, physical) to test and refine concepts.
• Strong understanding of customer needs and user experience (installer, end-user, specifier).
• Excellent commercial awareness and ability to balance cost, functionality, and aesthetics.
• Demonstrated ability to lead design projects with a creative and solutions-focused mindset.

Desirable Skills

• Knowledge of material science and properties.
• Experience using FEA tools for stress and failure analysis.
• Previous experience in luminaire development.
• Familiarity with IEC 60598-1 and relevant lighting safety standards.
• Experience with Teamcenter PLM.
• Rendering and visualization skills using tools like Keyshot.
• Experience with ray tracing and optical design.
• Knowledge of sustainable design and manufacturing practices.

Key Behaviours

• Strong communication and interpersonal skills.
• Excellent problem-solving and analytical abilities.
• Organised, adaptable, and self-motivated.
• A collaborative team player with effective leadership skills.