iO Associates
Senior Mechanical Design Engineer
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Job Description - Senior Mechanical Engineer
Overview
We are seeking an experienced Senior Mechanical Engineer to support the design, development, testing, and validation of advanced mechanical systems within a fast-paced product development environment.
This role combines mechanical design engineering with hands-on prototype development and laboratory testing, offering the opportunity to take products through the complete engineering lifecycle—from concept generation and detailed design through prototype validation, supplier collaboration, and production readiness.
Working alongside senior technical leaders and multidisciplinary engineering teams, you will contribute to complex engineering programmes while independently managing your own technical workstreams. The role requires a practical, detail-oriented engineer who enjoys balancing CAD-based design with experimental testing and real-world problem solving.
Key Responsibilities
Mechanical Design
- Develop, modify, and optimise 3D mechanical designs using SolidWorks.
- Produce detailed manufacturing drawings using industry-standard GD&T practices.
- Perform and document engineering calculations, including:
- Tolerance stack analysis
- Press and interference fit calculations
- O-ring and sealing design
- Bolt torque calculations
- Thermal expansion (CTE) assessments
- Basic stress calculations
- Support finite element analysis (FEA) activities, including model preparation, boundary conditions, result interpretation, and design optimisation.
- Participate in Design for Manufacturing (DFM) reviews with suppliers and manufacturing teams.
- Support Design Failure Mode and Effects Analysis (DFMEA) activities.
- Conduct vehicle or system packaging studies and 3D fit assessments where required.
- Participate in structured root cause investigations using methodologies such as 8D.
- Provide technical support during supplier and customer engineering discussions.
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Prototype Development & Testing
- Plan and execute Design of Experiments (DOE) within an engineering test laboratory.
- Set up and operate prototype test rigs, instrumentation, and data acquisition systems.
- Support prototype assembly, development builds, and engineering validation activities.
- Analyse and interpret experimental data using MATLAB or equivalent engineering software.
- Produce clear technical reports and communicate findings to project teams.
- Support testing activities at supplier, customer, or development facilities where required.
Essential Qualifications
- Bachelor's Degree in Mechanical Engineering or a related engineering discipline.
- Minimum of 5 years' experience in mechanical product development within the automotive or comparable engineering sector.
- Strong proficiency with SolidWorks for 3D modelling and manufacturing drawing creation.
- Excellent understanding of Geometric Dimensioning and Tolerancing (GD&T).
- Experience using structural simulation software such as SolidWorks Simulation or Ansys.
- Ability to perform engineering design calculations supporting mechanical design decisions.
- Hands-on experience working within an engineering test or research and development laboratory.
- Experience planning and executing Design of Experiments (DOE).
- Ability to analyse engineering test data using MATLAB or equivalent software.
- Experience conducting DFMEA.
- Knowledge of structured problem-solving methodologies such as 8D.
- Strong written and verbal communication skills.
- Experience working with suppliers and customers in technical environments.
- Ability to work independently while collaborating effectively within multidisciplinary teams.
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Desirable Skills & Experience
- Experience designing automotive actuators, dampers, suspension, or other electromechanical systems.
- Practical experience performing finite element analysis, including model creation, meshing, and post-processing.
- Familiarity with Design Verification Plan and Report (DVP&R) processes.
- Master's Degree in Mechanical Engineering or a related discipline.
What We're Looking For
We're looking for an engineer who combines strong analytical capability with practical, hands-on engineering experience. You should be comfortable taking ownership of technical challenges, balancing CAD design with prototype development, and working across the full product development lifecycle.
This position offers the opportunity to see your designs progress from initial concept through engineering validation and into production, working closely with experienced engineers, suppliers, and cross-functional teams in a collaborative and innovative development environment.
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