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
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