Senior Mechanical Payload Integrator – Aerospace & Defence

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

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.