Design Engineer – UAV Airframe

20 hours ago

London Area, United Kingdom Defy Aerospace Full time

About Us:

At Defy Aerospace, we are building next-generation unmanned aerial systems (UAS) designed for demanding environments and real-world applications. Our engineers take ownership of complete UAV design engineering — spanning structures, subsystems, integration, and compliance — while working in a fast-paced, innovation-driven environment.

We are seeking a Design Engineer with 2-5 years of experience to deliver design engineering activities across the UAV program in the UK.

Key responsibilities:

  • Take ownership of 
    UAV design engineering
     from concept through prototyping and testing.
  • Lead structural and subsystem design, covering:

-External geometry (skins, aerodynamic surfaces, control surfaces).

-Internal layouts (spars, ribs, bulkheads, payload & battery bays, mounting trays).

  • Develop detailed 
    3D CAD models, assemblies, and 2D drawings
     with
    GD&T
    using 
    CATIA V5 / 3DEXPERIENCE (mandatory)
    .
  • Design 
    composite sandwich structures
     (carbon fibre + honeycomb/foam cores) and 
    metallic structures
     (CNC-machined aluminium/titanium).
  • Define 
    load paths and structural concepts
     (wing box, fuselage frames, landing gear attachments).
  • Integrate 
    propulsion mounts, avionics racks, payload hardpoints, and access hatches
     into the structure.
  • Perform 
    preliminary structural analysis
     (stiffness, stress, buckling) and work with analysis engineers for FEA/CFD validation.
  • Manage 
    mass properties and CG discipline
     across components and subsystems.
  • Generate and maintain 
    BoMs, revision control, and design documentation
     in line with aerospace gated processes.
  • Follow strict 
    documentation and data discipline
    : ensure drawings, BoMs, weight reports, and design changes are traceable and released through proper processes.
  • Participate in 
    PDR, CDR, TRR
     and deliver design packages to required standards.
  • Support 
    tooling design, prototyping, and hands-on testing
     during builds and flight trials.

Required Qualifications:

  • Bachelor's/Master's degree in Aerospace, Mechanical, or Structures Engineering.
  • 2-5 years
     of experience in UAV/aircraft design engineering.
  • Hands-on expertise in 
    CATIA V5 / 3DEXPERIENCE (mandatory)
    , including surface modelling.
  • Strong knowledge of 
    composite and metallic design/manufacturing methods
     (pre-preg, autoclave, CNC).
  • Experience designing 
    primary load-carrying structures
     (spars, ribs, bulkheads).
  • Understanding of 
    FEA processes
     (ANSYS/NASTRAN/Abaqus) and CFD workflows.
  • Proven experience in 
    documentation, change management, and gated aerospace processes
     (PDR, CDR, TRR).

Join us and :

  • Own the complete design of 
    next-gen UAVs
  • Work at the intersection of 
    innovation and applied aerospace technology
    .

  • Join a small, high-impact team building systems designed to perform in challenging conditions.

  • Contract:
     Six months (extendable)

We strongly encourage UK-based engineers — including those on Graduate or PSW visas — to apply.

This role offers the opportunity to gain hands-on, industry-relevant experience working on next-generation aerial systems alongside a focused, high-performance engineering team.

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