Mechanical Design Engineer

Mechanical Design Engineer

Filtronic

Sedgefield, United Kingdom

Purpose of Role

To provide end-to-end mechanical engineering support and leadership for advanced high-frequency RF systems, modules and amplifiers, ensuring that mechanical performance, thermal efficiency, reliability, manufacturability, quality and cost requirements are achieved.

The role will involve the design of mechanically robust, lightweight and thermally efficient assemblies for demanding industrial, payload and high-reliability environments, including space-related applications.

Summary of Responsibilities

Mechanical Design and Development

• Design precision mechanical components and assemblies for RF modules and systems, including lightweight structural enclosures, heatsinks, liquid cooling solutions and waveguide-based architectures.
• Develop modular mechanical architectures suitable for integration into larger payload or system-level assemblies, considering mass, volume, mounting interfaces and serviceability.
• Ensure designs meet RF, thermal, mechanical and environmental requirements, including EMI shielding, structural stiffness, tolerance control, CTE compatibility, vibration, shock and ingress protection.
• Create detailed 3D CAD models and engineering drawings using SolidWorks.
• Select appropriate materials, finishes and manufacturing processes to support product performance, reliability and manufacturability.

Thermal and Structural Analysis

• Perform thermal analysis and simulation, including CFD and conjugate heat transfer, to validate cooling strategies for high-power RF amplifiers and electronic assemblies.
• Conduct structural and dynamic analysis using FEA for vibration, shock, fatigue and other load-case conditions typical of high-reliability payload deployment.
• Review mechanical properties of parts and assemblies, including thermal performance, mechanical stress and environmental robustness.
• Validate simulation models through physical testing and correlation with measured data.

RF-Aware Mechanical Engineering

• Work closely with RF, electronics and systems engineers to optimise mechanical features that influence RF performance, including cavity geometry, surface finish, plating, tolerances and material selection.
• Design mechanical solutions with consideration for waveguide structures, micro-machined geometry, PCB integration and precision alignment.
• Support electromechanical product concept design in collaboration with RF, electronics and PCB design teams.

Manufacturing Support

• Develop designs for manufacturability, assembly and cost reduction using processes including CNC machining, die-casting, additive manufacturing and sheet metal manufacture.
• Generate manufacturing documentation including bills of materials, GD&T drawings and assembly instructions.
• Manage and control engineering drawings and documentation in accordance with Drawing Office standards and company processes.
• Support suppliers and production teams during prototype build, first article approval and continuous improvement activity.
• Contribute to design reviews as part of the company’s ISO and NPI processes.
• Support engineering change activity through ECN/ECO processes.

Prototyping and Testing

• Support the build and test of mechanical prototypes and development hardware.
• Support environmental and reliability testing including thermal cycling, humidity, vibration, thermal shock and drop testing.
• Work with test and process engineering to develop production hardware, jigs and fixtures to optimise build and test efficiency.
• Provide technical support to internal stakeholders, customers and external partners throughout the product lifecycle.

Requirements

Skills, Experience and Qualifications

• Degree or equivalent qualification in Mechanical Engineering.
• Strong 2D and 3D CAD skills, with SolidWorks preferred.
• Experience designing high-precision mechanical assemblies, ideally for constrained, high-reliability or technically demanding environments.
• Understanding of PCB integration, RF shielding and EMI/EMC considerations.
• Strong understanding of materials and manufacturing processes, preferably including CNC machining of aluminium alloys and lightweight structures.
• Excellent understanding of GD&T and engineering drawing standards.
• Experience developing drawings for machined, cast, moulded, punched or sheet metal parts.
• Ability to work effectively within cross-functional engineering teams.
• Experience with PDM/PLM systems and engineering change processes.
• Must be a highly motivated individual able to interface effectively with internal and external customers.

Desirable Skills and Experience

• Experience with payload systems or deployment environments such as space, aerospace, defence or telecoms infrastructure.
• Experience with industrial system design.
• Hands-on experience with FEA and thermal simulation tools, preferably SolidWorks Simulation or SolidWorks Flow.
• Familiarity with RF/mmWave product development, including waveguides, filters, amplifiers and high-frequency assemblies.
• Knowledge of lightweighting techniques and structural optimisation for mass-constrained designs.
• Experience with high-reliability and qualification-driven design standards, such as MIL-STD or ECSS.
• Familiarity with environmental testing such as thermal vacuum or vibration qualification.
• Knowledge of RoHS and WEEE compliance.
• Experience supporting supplier development, first article inspection or production readiness activity.

Personal Attributes

• Strong problem-solving ability with excellent attention to detail.
• Positive, proactive and hands-on approach.
• Ability to manage multiple projects and priorities in parallel.
• Clear and effective communicator across multidisciplinary teams, suppliers and customers.
• Self-motivated, adaptable and eager to learn new tools, processes and technologies.
• Team player with a strong customer focus.