Senior Mechanical Design Engineer in Aerospace Tooling, Lee on the Solent

About Us

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
• Career development and progression opportunities