KDC Group Services Ltd
Wind Tunnel - Model Maker / Rigger
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Wind Tunnel Model Maker
We are seeking a highly skilled and detail-oriented Wind Tunnel Model Maker to join our engineering team supporting wind tunnel activity. This hands-on role involves the extremely precise construction, assembly, modification, and hand finishing of aerodynamic models used in wind tunnel testing. You will work at the intersection of fine craftsmanship and mechanical engineering, producing high-accuracy components that directly support research and development.
Key Responsibilities
- Fabricate and assemble complex scale models and rigs for wind tunnel testing to micrometre-level tolerances.
- Interpret technical drawings, CAD models, and engineering specifications to guide build processes.
- Use workshop machinery including lathes, milling machines, grinders, and surface finishing tools to high standards of accuracy.
- Work with delicate materials such as aluminium, composites, plastics, and thin-walled structures.
- Ensure models are robust, precise, and safe for wind tunnel testing environments.
- Collaborate with engineers and aerodynamicists to modify and optimise models during test campaigns.
- Maintain a clean, safe, and well-organised workshop environment.
- Support occasional troubleshooting, reworking, and model adaptation tasks under time constraints.
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Essential Skills
- Proven experience in high-precision model making, ideally in aerospace, motorsport, or R&D environments.
- Strong workshop background with proficiency in manual and CNC machining, hand tools, and finishing techniques.
- Exceptional attention to detail and ability to work with fragile or finely detailed components (e.g. hand finishing 0.1mm diameter drill holes).
- Comfortable working from complex engineering drawings and CAD outputs.
- Knowledge of materials and methods commonly used in model and rig fabrication (metals, polymers, composites), e.g. 3D printing.
- Understanding of mechanical tolerances, fits, and fastener techniques.
- Calm and methodical, even when under pressure.
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Desirable Skills
- Experience in wind tunnel model rigging or aerodynamic testing environments.
- Familiarity with instrumentation integration (e.g. pressure tappings, strain gauges).
- Strong problem-solving mindset with the ability to adapt quickly.
- Good communication skills and a collaborative approach to working with multidisciplinary teams.
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