Senior Mechanical Design Engineer – Flight Simulation Hardware
Crawley (4 days onsite, 1 day WFH)
Full-time Permanent
The Opportunity
We are working with a highly innovative engineering organisation operating at the forefront of flight simulation technology, delivering advanced hardware solutions to global aviation training providers.
They are seeking a Senior Mechanical Design Engineer to play a key role in the development of high-performance, safety-critical hardware systems, contributing to next-generation flight simulators used worldwide.
This is an excellent opportunity for an engineer who thrives in a fast-paced, hands-on environment, and wants to work on complex, real-world mechanical systems with global impact.
Key Responsibilities
- Design and develop mechanical hardware systems for advanced simulation platforms
- Create and detail load-bearing structural components, including:
- Motion platform frames
- Cockpit structures
- Instrument and display mounting systems
- Access platforms
- Perform stress analysis using both:
- Hand calculations
- Finite Element Analysis (FEA)
- Produce formal calculation packs and stress reports to support design reviews and approvals (SRR, PDR, CDR)
- Develop detailed 3D CAD models and technical drawings
- Collaborate with cross-functional teams including systems, electrical, and software engineers
- Support testing, validation, and troubleshooting of hardware systems
- Engage with suppliers to support component sourcing and integration
- Contribute to continuous improvement and innovation in hardware design
Key Requirements
- Degree in Mechanical Engineering (or related discipline)
- Proven experience in mechanical design of structural systems within industries such as:
- Aerospace
- Automotive
- Wind energy
- Heavy engineering or similar
- Strong experience with:
- Stress analysis (hand calculations + FEA)
- Structural design under static, dynamic, and fatigue loading
- Ability to produce engineering calculation reports and documentation
- Proficiency in 3D CAD tools (Creo / Pro-E or CATIA V5 preferred)
- Experience with PLM systems (e.g. Windchill, Teamcentre) is advantageous
- Strong understanding of design for manufacture and assembly (DFM/A)
- Experience working within regulated or safety-critical environments
Desirable Experience
- Flight simulation or aerospace systems
- Motion systems, actuation, or dynamic mechanical assemblies
- Experience working in multi-disciplinary engineering teams
- Exposure to engineering design reviews and lifecycle processes
What’s on Offer
- Work on cutting-edge simulation hardware used globally
- High-impact engineering projects with real-world application
- Collaborative, fast-moving engineering environment
- Strong opportunities for technical growth and career progression
