AALTO, a global leader in Stratospace

Based in Farnborough, AALTO is an Airbus subsidiary that manufactures, operates, and delivers services with its solar-powered, stratospheric platform: Zephyr.

Zephyr’s persistence enables continuous flight for months at a time. Its current flight-time record of over 67 days in the stratosphere. From above 60,000+ft, or 20km above ground, AALTO can deliver several applications including direct-to-device connectivity and high-resolution Earth observation.

AALTO operates in a new operational layer between most of air traffic and low-Earth orbit, Stratospace. This is where high-altitude platforms led by Zephyr deliver services to commercial and government partners. We can help monitor environments, observe borders, track natural disasters and connect unconnected communities.

Join us as we create a new domain of aerospace: Stratospace. You’ll be part of a highly-skilled, innovative and passionate group of people – Team AALTO. Together, we can Unlock Stratospace.

About The Role

Join AALTO's innovative engineering team as a Mechanical Design Engineer, contributing to the design, development, and delivery of mechanical systems for Zephyr and future high-altitude aircraft platforms.

Working within a multidisciplinary engineering environment, you will develop mechanical design solutions that support the full product lifecycle, from concept development and detailed design through to manufacture, integration, testing, and operational support. This is an excellent opportunity to build expertise in advanced aerospace technologies, lightweight composite structures, and cutting-edge aircraft design while working alongside experienced engineers and technical specialists.

The role offers significant opportunities for professional growth, allowing you to progressively take ownership of more complex engineering challenges as your technical expertise develops.

Responsibilities

• Support the development of concept and detailed mechanical design solutions that meet product and system requirements.
• Create 3D CAD models, assemblies, and engineering drawings using SolidWorks or equivalent CAD software.
• Generate and maintain product definition data within PDM and PLM systems.
• Deliver allocated design activities in line with project schedules, engineering processes, and airworthiness standards.
• Support design reviews through the preparation of engineering analyses, presentations, technical reports, and supporting evidence.
• Provide engineering support to manufacturing activities, helping resolve production and assembly-related issues.
• Assist with the planning, coordination, and execution of mechanical testing and qualification programmes.
• Collaborate with manufacturing, procurement, integration, and test teams to ensure practical and manufacturable design solutions.
• Implement engineering changes in accordance with configuration management and change control processes.
• Contribute to continuous improvement initiatives that enhance quality, efficiency, manufacturability, and cost performance.
• Support root cause investigations and failure analysis activities associated with design, manufacturing, or operational issues.
• Develop knowledge and expertise in composite structures, aerospace engineering practices, and Design Organisation processes.
• Effectively manage assigned work packages, communicating progress, risks, and issues to technical leads and managers.