Senior Mechanical Design Engineer

Overview

Rapiscan Systems is a global leader in detection technology, delivering advanced cargo and vehicle inspection solutions used at ports, borders, military facilities, and high-security checkpoints worldwide. Our systems help combat terrorism, drug smuggling, illegal immigration, and trade fraud through industry-leading X-ray imaging and innovative engineering.

Role Overview

We are seeking a Senior Mechanical Engineer to join our Cargo and Vehicle Inspection (CVI) Engineering team in Stoke-on-Trent. This role offers the opportunity to work on complex, safety-critical products across the full lifecycle — from concept and new product introduction through to continuous improvement in manufacture.

Responsibilities

• Design complex mechanical systems and assemblies, including fabricated structures, sheet metalwork, machined components, and hydraulic systems.
• Produce general arrangement and assembly drawings, work instructions, and bills of materials.
• Ensure mechanical designs fully support and integrate electrical and other system components.
• Participate in engineering design reviews, project kick‑off meetings, and customer meetings as required.
• Complete design sign‑off to manufacturing and process Engineering Change Requests (ECRs) and Engineering Change Orders (ECOs) through the document control system.
• Collaborate with US (Billerica, Boston) and India (Hyderabad) engineering teams using global PLM systems.
• Lead and support cross‑functional engineering teams to deliver new product designs.
• Apply engineering calculations to support designs, including structural analysis, thermodynamics, and fluid flow, validating solutions through modelling or testing.
• Promote company values of Integrity, Innovation, Accountability, and Teamwork.
• Identify and report quality issues to ensure corrective action and continuous improvement.

Qualifications

• SolidWorks experience is essential, with a strong track record in fabricated structures, sheet metal, and machined components.
• Experience with Autodesk Inventor or other CAD packages is desirable.
• Bachelor’s degree or higher in Mechanical Engineering preferred; equivalent industry experience will be considered.
• Experience in mechanical stress and thermal modelling is advantageous.
• Strong experience developing new design concepts for heavily fabricated products.
• Proven capability in the design of complex electro‑mechanical assemblies.
• Experience with design for manufacture, ideally within a production environment.

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