Lead Engineer Job Description
We are seeking a highly skilled engineer to lead the development of cutting-edge protection systems. This is an exciting opportunity to utilize advanced manufacturing techniques and push performance forward.
The successful candidate will be responsible for developing novel components, refining advanced manufacturing processes, and running rigorous performance tests.
This role requires a strong understanding of high-energy impact physics and material response under dynamic loads. The ideal candidate will have expertise in protection systems including design and testing of composites, as well as experience with additive manufacturing.
The Lead Engineer will be responsible for creating CAD models, performing nonlinear FEA, and applying optimisation tools. They will also be responsible for operating and tuning SLS polymer printing systems, managing data analysis and redesign.
Key Skills and Qualifications
* BEng/MEng (minimum) in Mechanical, Materials, Aerospace Engineering, or a related discipline;
* Expertise in protection systems including design and testing of composites;
* Strong understanding of high-energy impact physics and material response under dynamic loads;
* Previous experience with additive manufacturing including parameter tuning and process troubleshooting;
* Proficient in SolidWorks and nonlinear FEA tools (Ansys, Abaqus);
* End-to-end ownership of at least one hardware product from concept through prototyping and into released production;
* Experience leading materials and process R&D to achieve performance and cost targets at scale;
* Experience mentoring junior engineers and communicating progress to defence customers.
Job Responsibilities
* Product Ownership: Full cradle-to-launch responsibility for protection plates and extremity protection systems.
* Design & Simulation: Create CAD models, perform nonlinear FEA, and apply optimisation tools.
* Additive Manufacturing: Operate and tune SLS polymer printing systems, manage data analysis and redesign.
* Ballistics R&D: Lead test planning, internal trials, and collaborate with accredited test houses.
* Materials & Process Innovation: Develop and refine powder feedstocks, slicing strategies, and print conditions to meet cost/performance targets.
* Compliance & Documentation: Author BoMs, DFMEAs, ISO quality records, and CE/UKCA technical files.
* Stakeholder Engagement: Liaise with suppliers, test labs, and defence customers.