Senior Mechanical Design Engineer

DFS Composites Limited; United Kingdom; On-site; GBP 50,000 - 70,000; Full time

Benefits offered by this job

Opportunity to work on innovative projects

Collaborative engineering environment

Career development opportunities

Job summary

DFS Composites Limited is seeking a Senior Mechanical Design Engineer to take ownership of the full lifecycle of tooling solutions, from concept to commissioning. This role plays a key part in delivering innovative engineering solutions in the aerospace and renewable energy sectors.

The ideal candidate will lead design activities, produce CAD models, and ensure compliance with industry standards, while mentoring junior engineers. Opportunities for career development in a collaborative engineering environment are provided.

Qualifications

• Minimum of 5 years’ relevant industry experience.
• Experience in aerospace and composite tooling.
• Knowledge of mechanisms and automation systems.

Responsibilities

• Lead and manage design activities across multiple projects.
• Produce high-quality CAD models, engineering drawings, and BOMs.
• Conduct risk assessments and DFMEAs.

Skills

CAD modeling

Structural simulations

Engineering calculations

Compliance with codes and standards

Job description

About Us

DFS Composites Ltd designs and manufactures cutting-edge composite tooling solutions for a global customer base across the wind energy and aerospace sectors. With a strong focus on sustainability and innovation, we pride ourselves on delivering high-performance engineering solutions that support the future of clean energy and advanced manufacturing.

The Role

We are seeking a Senior Mechanical Design Engineer to join our growing team. This role offers the opportunity to take ownership of the full lifecycle of tooling solutions — from initial concept through to detailed design, testing, inspection, and commissioning.

You will play a key role in delivering innovative engineering solutions while working closely with cross-functional teams and customers on a diverse range of projects.

Key Responsibilities

Design

• Lead and manage design activities across multiple projects
• Develop concepts from customer requirements through to final design
• Produce high-quality CAD models, engineering drawings, and Bills of Materials (BOMs)
• Perform structural simulations using FEA tools
• Carry out engineering calculations to support design decisions
• Ensure compliance with relevant codes, standards, and internal procedures
• Review and check designs, drawings, and calculations
• Specify appropriate components and materials
• Maintain up-to-date knowledge of engineering principles, technologies, and best practices

Documentation

• Prepare design reports, FEA reports, and calculation documentation in line with ISO standards
• Conduct risk assessments and DFMEAs
• Produce user manuals and supporting technical documentation.
• Work effectively within a multidisciplinary team
• Participate in customer meetings as required
• Collaborate closely with production and installation teams throughout design and manufacturing phases
• Mentor and support junior engineers
• Develop and document test procedures for new products
• Carry out hands-on testing and validation activities
• Travel to customer and manufacturing sites to support installation, testing, and fault finding

Required Experience

• Minimum of 5 years’ relevant industry experience
• Aerospace tooling experience
• Composite tooling experience
• Experience with lifting, handling, and positioning jigs
• Knowledge of mechanisms and automation systems

What We Offer

• Opportunity to work on innovative, high-impact projects in renewable energy and aerospace
• A collaborative and forward-thinking engineering environment
• Career development and progression opportunities