Lead / Senior Mechanical Design Engineer (Drivetrain) - Malloy Aeronautics Ltd : Job Details

Job title: Lead / Senior Mechanical Design Engineer (Drivetrain)

Location: Maidenhead, Berkshire

The Malloy Aeronautics Team:

Malloy Aeronautics Limited specializes in the development of heavy lift unmanned air vehicles (UAVs) for both civilian and military uses. Located in Berkshire, our operations are notable for their focus on in-house design and manufacturing. This vertical integration means we control the production of most aircraft components on-site, enhancing our ability to innovate and maintain high standards across all stages of development.

About The Role:

We are seeking an accomplished Lead or Principal Mechanical Design Engineer to take full ownership of the mechanical design for drivetrain components such as electrical motors and generators, electronic speed controllers (ESCs), and the associated rigs and tooling. You will lead one or more junior designers, ensure quality, consistency, and timely delivery of designs, while liaising closely with mechanical, electromagnetic, and thermal analysts both within the team and externally. This is a hands-on technical leadership role with significant influence over our most advanced R&D projects.

Ability to hold Security Clearance – 5 years residence in the UK

What you’ll being doing (but not limited too):

• Taking ownership of the mechanical design across drivetrain components, including motors, generators, and ESCs.
• Leading, mentoring, and reviewing the work of junior designers to ensure high-quality outputs.
• Creating tooling and rigs to support both assembly lines and new product developments.
• Designing for weight-constrained applications and optimising structural efficiency.
• Building & reviewing 3D models in SolidWorks of composite components, structural assemblies, and other metallic & plastic parts.
• Applying Geometric Dimensioning and Tolerancing (GD&T) principles to ensure precision and manufacturability.
• Liaising with mechanical, EM, and thermal analysts to integrate analysis outputs into design decisions.
• Developing build instructions and technical documentation for manufacturing teams.
• Analysing materials, structural integrity, and lightweight designs for high-performance applications.
• Selecting production processes for cost-effective, high-quality components.
• Considering electrical aspects, such as winding patterns, electrical steel, and creepage/clearance requirements.
• Interface with other engineering groups on collaborative projects to deconflict integration issues and execute against the integration plan.
• Demonstrating novel, successful designs using rapid prototyping techniques.
• Basic FEA knowledge, backed with hand calculations to ensure parts are designed mass efficiently with appropriate safety factors.

Essential Skills and Experiences:

• A degree in Mechanical Engineering or a related field is mandatory.
• Proven leadership in guiding junior designers and owning end-to-end mechanical design.
• Proficiency in CAD software, with SolidWorks being highly desirable.
• Strong experience with GD&T and design for manufacturing principles.
• Extensive knowledge of electrical rotating machinery (mechanical and electrical aspects).
• Familiarity with bearings, lightweight structural designs, and performance optimisation.
• Excellent problem-solving skills and attention to detail.
• Strong communication and collaboration skills.

Benefits you may be eligible for:

• We have obtained Bronze Level Armed Forces Covenant
• Company Pension Scheme
• Access to 24 Hour Helpline
• Employee Stock Purchase Plan (BAE Systems Share Incentive Plan)
• Cycle to work scheme
• Additional holiday with long service
• Healthcare cash plan
• 20 Days of Annual Leave Bank Holidays
• Statutory Sick Pay
• Three-Day Long Weekend Every Fortnight (Fri-Sun)
• Freshly Cooked Lunch on working Fridays
• Casual Dress
• On-Site Parking

Why Malloy Aeronautics?

Our company benefits from a streamlined process where engineering teams are involved in the entire lifecycle of our UAVs — from initial design through to production. This setup not only speeds up the development process but also improves the efficiency and effectiveness of our product launches. We value professionals who have a background in both research and development (R&D) and design for manufacture, as their expertise is crucial to our rapid and precise product development cycle.

Please be aware that many roles working for Malloy Aeronautics will be subject to both security and export control restrictions. These restrictions mean that factors including your nationality, any previous nationalities you have held, and your place of birth may limit those roles you can perform for the organisation.

Malloy Aeronautics is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees. We welcome candidates from all backgrounds and particularly from sections of the community who are currently underrepresented within our industry, including women, ethnic minorities, people with disabilities and LGBTQ+ individuals.

We also want to make sure that our recruitment processes are as inclusive as possible. If you have a disability or health condition (for example dyslexia, autism, an anxiety disorder etc.) that may affect your performance in certain assessment types, please speak to your recruiter about potential reasonable adjustments.

Note: If you have not heard from our recruitment department within 14 days, unfortunately you have not been successful.

Malloy Aeronautics and BAE Systems will collect and process information about you that may be subject to data protection laws. For more information about how we use and disclose your personal information, how we protect your information, our legal basis to use your information, your rights and who you can contact, please refer to the relevant sections of our Privacy notice.