Senior Design Engineer

Aldena Associates; Ashton-under-Lyne; On-site; GBP 45,000 - 65,000; Full time

Job summary

A leading market manufacturer is seeking a Senior Design Engineer to join their innovative New Product Development team. This role focuses on the end-to-end development of sustainable lighting products, requiring strong mechanical design skills and project management experience. The successful candidate will lead complex projects, mentor junior engineers, and continuously improve product designs. A passion for innovation and a keen eye for detail are essential for success in this role.

Qualifications

• 5+ years of industry experience delivering complex projects.
• Proficient in designing tooled components and 3D CAD skills.

Responsibilities

• Lead delivery of complex projects in accordance with NPD Gate process.
• Design products that meet specifications, timelines, and quality standards.

Skills

Communication

Problem Solving

Analytical Abilities

Leadership

Education

Degree in Mechanical or Product Design

Tools

Solid Edge

Microsoft Office Suite

Teamcenter PLM

Keyshot

Job description

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Full Job Description

Job Title: Senior Design Engineer

Department:New Product Development (NPD)

Reports To: Head of Design / Design Manager

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

1. Lead the delivery of complex, large-scale projects in strict accordance with the NPD Gate process.
2. Design and develop products that meet all project specifications, timelines, and quality standards.
3. Demonstrate a thorough understanding of project requirements and communicate design rationale clearly, challenging and refining specifications where appropriate.
4. Deliver safe, reliable, and commercially successful design solutions using tools such as FMEA.
5. Accurately complete all required documentation to support design outputs.
6. Utilize a range of design tools including sketches, models, prototypes, and 3D CAD to effectively communicate ideas.
7. Create precise CAD and PLM data in line with best practice standards.
8. Develop accurate, costed Bills of Materials (BoMs) for all new designs.
9. Investigate and address cost variances, proposing solutions and communicating with key stakeholders.
10. Produce production-ready components and assemblies, integrating insights from research into product technologies and structures.
11. Continuously improve existing products and processes, identifying opportunities for innovation and efficiency.
12. Enhance installation methodologies by developing intuitive, safe, and user-friendly solutions supported by physical samples and clear instructions.
13. Apply root cause analysis to resolvedesign issues, implementing robust corrective actions.
14. Mentor and support Trainee Design Engineers and Apprentices, fostering their technical and professional growth.
15. 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.
• Knowledge of material science and properties.
• Experience using FEA tools for stress and failure analysis.
• 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.