Description

Senior Mechanical Design Engineer – Flight Simulation Hardware

Crawley (4 days onsite, 1 day WFH)
Full-time | Permanent

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.

• 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

• 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

• 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

• 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