Senior Mechanical Integration Engineer

Copello Global; Aberporth; Hybrid; GBP 50,000 - 60,000; Full time

Benefits offered by this job

Private Medical Insurance

Pension contribution up to 10%

25 days’ annual leave

Employee reward scheme

Flexible hybrid working

Job summary

Copello Global is seeking a Senior Mechanical Payload Integration Engineer to design and integrate sensors and mission equipment on high-performance uncrewed aircraft. You will drive from concept through CAD, fabrication, bench tests and flight trials, ensuring hardware readiness for demanding environments.

The role emphasizes cross-disciplinary collaboration with structural, aerodynamic and systems teams, plus hands-on problem solving and end-to-end accountability for the payload integration.

Qualifications

• Degree in Mechanical/Aerospace Engineering or related discipline.
• Experience in mechanical design, structural integration or hardware packaging, preferably in aerospace/defence/UA systems.
• Strong 3D CAD capability (SolidWorks, CATIA or Fusion 360).
• Experience with FEA or other mechanical analysis techniques.
• Understanding of manufacturing processes including machining, additive manufacturing and composites.
• Knowledge of fasteners, tolerancing and GD&T.
• Experience with environmental testing, especially vibration and shock.
• Hands-on approach and ability to troubleshoot hardware issues.
• Clear engineering/test documentation and cross-disciplinary collaboration.

Responsibilities

• Own broad mechanical integration challenges from concept to hardware, testing and flight.
• Design mounting brackets, adapter plates, pods and structural interfaces for sensors and mission equipment.
• Create 3D CAD models, production drawings, BOMs and assembly documentation.
• Perform analyses to validate designs, including FEA and thermal assessments.
• Assess mass, center of gravity and aerodynamic impacts across flight conditions.
• Troubleshoot fitment, structural, vibration and shock issues during integration and flight trials.
• Collaborate with manufacturers using CNC, additive manufacturing and composites.
• Support testing, validation and qualification of integrated payload systems.

Skills

Mechanical design

Structural integration

Hardware packaging

3D CAD

FEA

Vibration testing

Documentation

Cross-disciplinary

Education

Bachelor's degree in Mechanical Engineering

HNC/HND or Modern Apprenticeship in related discipline

Tools

SolidWorks

CATIA

Fusion 360

Job description

Senior Mechanical Payload Integration Engineer – Aerospace & Defence- £50,000-£60,000

Are you a Senior Mechanical Engineer who enjoys solving complex integration problems and seeing your designs become real flight hardware?

This is an opportunity to work at the point where aircraft, payloads and mission capability come together — designing and integrating sophisticated sensors and mission systems onto high-performance uncrewed aircraft used across Defence, Security and Space.

You’ll work closely with structural, aerodynamic and systems engineers, as well as payload manufacturers, to solve challenging mechanical integration problems and ensure hardware is ready for demanding operational environments.

From concept and CAD through to bench integration, testing and flight-line trials, you’ll see your engineering decisions make a direct difference to the aircraft and its mission.

A Role at the Heart of Payload Integration

You’ll take ownership of a broad range of mechanical integration challenges, including:

• Designing custom mounting brackets, adapter plates, pods and structural interfaces for sensors and mission equipment
• Creating detailed 3D CAD models, production drawings, BOMs and assembly documentation
• Performing FEA, thermal assessments and structural evaluations to validate your designs
• Assessing payload mass, centre of gravity and aerodynamic impacts across different flight conditions
• Troubleshooting fitment, structural, vibration and shock issues during integration and flight trials
• Working with structural analysts and aerodynamicists to optimise aircraft and payload interfaces
• Collaborating with manufacturers to deliver hardware using CNC machining, additive manufacturing and composites
• Supporting testing, validation and qualification of integrated payload systems
• Getting hands-on with hardware and resolving problems when the design meets the real world

This isn’t a role where you hand a design over and move on. You’ll be involved from engineering concept through to hardware, testing and flight.

What Makes This Opportunity Different?

You’ll work on problems that sit across traditional engineering boundaries.

A successful payload integration engineer needs to understand more than brackets and drawings. You’ll consider structural loads, vibration, thermal behaviour, mass properties, aerodynamic effects, manufacturing constraints and the practical realities of installing and operating mission equipment on an aircraft.

The programmes move quickly, priorities can change, and sometimes the best engineering solution is the one that can be designed, built and tested quickly. You’ll be trusted to use engineering judgement, make practical decisions and know when further analysis is genuinely needed.

You’ll also have the opportunity to take on increasing technical ownership and help develop engineers earlier in their careers.

What You’ll Bring

We’re looking for an experienced mechanical or aerospace engineer with a strong interest in hardware integration and real-world problem solving.

You’ll ideally have:

• A degree in Mechanical Engineering, Aerospace Engineering or a related discipline, or an appropriate Modern Apprenticeship with HNC/HND qualifications
• Experience in mechanical design, structural integration or hardware packaging, ideally within aerospace, defence or UAS
• Strong 3D CAD capability, such as SolidWorks, CATIA or Fusion 360
• Experience with FEA or other mechanical analysis techniques
• Understanding of manufacturing processes including machining, additive manufacturing and composites
• Knowledge of fasteners, tolerancing and geometric dimensioning
• Experience working with environmental testing, particularly vibration and shock
• A practical, hands-on approach and the confidence to investigate problems at the hardware level
• The ability to communicate clearly through concise engineering and test documentation
• A willingness to work across disciplines when the programme demands it

Why Join?

• Work directly on mission-critical uncrewed aircraft and payload technology
• Own engineering problems from CAD to integration to flight
• Work across mechanical, structural, aerodynamic and mission-system interfaces
• Get hands-on with real hardware and flight trials
• Collaborate with teams across the UK, Portugal and internationally
• Develop your technical expertise while taking on greater responsibility
• Competitive salary and discretionary annual bonus
• Pension contribution of up to 10%
• Private Medical Insurance and Employee Assistance Programme
• 25 days’ annual leave plus Bank Holidays
• Employee reward and recognition benefits
• Flexible hybrid working, with a minimum of 3 days per week on site
• Clear opportunities for career and professional development
• Inclusive, high-performing culture with regular social events

Security & Travel

Due to the nature of the programmes, you’ll need to be eligible for and willing to undergo UK SC Security Clearance.

The role may involve occasional travel to UK and international sites, including Portugal, the US and Europe, as well as potentially supporting deployed operations.