Senior Mechanical Integrator

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

Job summary

Copello in the United Kingdom is seeking a Senior Mechanical Payload Integration Engineer to lead the integration of sensors and mission systems on high‑performance airborne platforms. You will own design, analysis and hardware qualification from concept to flight, ensuring robust, manufacturable solutions.

The role requires hands-on problem solving, cross‑discipline collaboration and the ability to manage complex interfaces under operational deadlines.

Qualifications

• Degree in Mechanical or Aerospace Engineering.
• Experience in mechanical design and hardware packaging, especially aerospace/ UAS.
• Strong CAD skills with SolidWorks/CATIA/Fusion 360.
• Experience with FEA or other mechanical analysis techniques.
• Understanding of manufacturing: machining, additive manufacturing, composites.
• Knowledge of fasteners, tolerancing and GD&T.
• Experience with environmental testing (vibration/shock).
• Hands-on approach and hardware-level problem solving.
• Clear communication through engineering/test documentation.

Responsibilities

• Design mounting brackets, adapter plates, pods and interfaces for sensors and mission equipment.
• Create detailed 3D CAD models, production drawings, BOMs and assembly docs.
• Perform FEA, thermal assessments and structural evaluations to validate designs.
• Assess payload mass, CG and aerodynamic impacts across flight conditions.
• Troubleshoot fitment, structural, vibration and shock issues during integration and flight trials.
• Collaborate with structural analysts and aerodynamicists to optimise interfaces.
• Work with manufacturers on CNC machining, additive manufacturing and composites.
• Support testing, validation and qualification of integrated payload systems.
• Hands-on with hardware to resolve problems when design meets real world.

Skills

3D CAD

FEA analysis

Mechanical design

Hands-on hardware

Cross-disciplinary collaboration

Documentation

Aerospace hardware integration

Education

Mechanical/Aerospace Engineering degree

HNC/HND modern apprenticeship

Tools

SolidWorks

CATIA

Fusion 360

Job description

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

Aberporth, West Wales | Hybrid | Permanent, Full-Time

Put Mission Payloads Into the Air

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.

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

You’ll be someone who sizes things by hand before reaching for simulation, can work effectively under pressure, and is comfortable making sensible engineering decisions when time and information are limited.

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.