DFS Composites Ltd designs and manufactures cutting-edge composite tooling solutions for a global customer base across the wind energy and aerospace sectors. With a strong focus on sustainability and innovation, we pride ourselves on delivering high-performance engineering solutions that support the future of clean energy and advanced manufacturing.
The Role
We are seeking a Senior Mechanical Design Engineer to join our growing team. This role offers the opportunity to take ownership of the full lifecycle of tooling solutions — from initial concept through to detailed design, testing, inspection, and commissioning.
You will play a key role in delivering innovative engineering solutions while working closely with cross-functional teams and customers on a diverse range of projects.
Key Responsibilities
Design
Lead and manage design activities across multiple projects
Develop concepts from customer requirements through to final design
Produce high-quality CAD models, engineering drawings, and Bills of Materials (BOMs)
Perform structural simulations using FEA tools
Carry out engineering calculations to support design decisions
Ensure compliance with relevant codes, standards, and internal procedures
Review and check designs, drawings, and calculations
Specify appropriate components and materials
Maintain up-to-date knowledge of engineering principles, technologies, and best practices
Documentation
Prepare design reports, FEA reports, and calculation documentation in line with ISO standards
Conduct risk assessments and DFMEAs
Produce user manuals and supporting technical documentation.
Work effectively within a multidisciplinary team
Participate in customer meetings as required
Collaborate closely with production and installation teams throughout design and manufacturing phases
Mentor and support junior engineers
Develop and document test procedures for new products
Carry out hands-on testing and validation activities
Travel to customer and manufacturing sites to support installation, testing, and fault finding
Required Experience
Minimum of 5 years’ relevant industry experience
Aerospace tooling experience
Composite tooling experience
Experience with lifting, handling, and positioning jigs
Knowledge of mechanisms and automation systems
What We Offer
Opportunity to work on innovative, high-impact projects in renewable energy and aerospace
A collaborative and forward-thinking engineering environment
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