Mechanical Design Engineer

Job DescriptionFiltronic is a leading designer and manufacturer of high-performance radio frequency (RF), microwave, and millimetre-wave (mmWave) subsystems, specialising in mission-critical communication networks. Since 1977, we have built a strong reputation as trusted partners to global technology leaders across the telecommunications infrastructure, aerospace and defence, space, and critical communications sectors. Our legacy of innovation and engineering excellence has positioned us at the forefront of advanced connectivity solutions worldwide, and we continue to grow as we deliver cutting-edge technology for some of the most exciting programmes in the industry.Joining Filtronic means becoming part of a team that combines decades of RF expertise with a collaborative, forward-thinking approach to solving complex communication challenges."Filtronic is on a rapid growth trajectory. With record revenues, landmark space and defence contracts, and a clear roadmap for innovation, this is the moment for exceptionally talented people to join us in shaping the future of high speed RF communications." (Nat Edington, Chief Executive Officer, Filtronic plc)Job Summary:The mechanical design engineer will be responsible for the end-to-end mechanical development of advanced high-frequency RF products. They will create detailed 3D CAD models, select appropriate materials and manufacturing methods and perform thermal and structural analysis to ensure all designs meet stringent performance, reliability, and environmental requirements.The mechanical design engineer will collaborate closely with cross-functional teams throughout the entire product lifecycle. This includes working with RF, electronics, process, systems and manufacturing engineers during concept development, prototype builds, testing, and validation. Must be a highly motivated individual able to interface effectively with internal & external customersRequirementsMechanical Design & Development * Design precision mechanical components and assemblies for RF modules, including housings, hermetic packages, heatsinks, waveguide structures, and test fixtures. * Create detailed 3D CAD models and manufacturing drawings. * Ensure designs meet stringent RF, thermal, mechanical, and environmental requirements (EMI shielding, stiffness, tolerancing, CTE matching, vibration, IP rating).Thermal & Structural Analysis * Perform thermal simulations (CFD, thermal, conjugate) to validate cooling system design and ensure reliable operation of high-power mmWave amplifiers and electronics. * Conduct structural analysis (FEA) for vibration, shock, fatigue, and drop-test conditions where required. * Confirm simulation assumptions through lab measurement and testing.RF-Aware Mechanical Engineering * Collaborate with RF and electronics engineers to optimise mechanical features that influence RF performance (cavity geometry, surface finish, plating, tolerances, material selection). * Design mechanical solutions with consideration for waveguide structures, micro-machined components, PCB integration, and precision alignment.Manufacturing Support * Develop designs for manufacturability (DFM) and assembly (DFA) using processes including CNC machining, die-casting, additive manufacturing and sheet metal manufacturing. * Generate manufacturing documentation, BOMs, GD&T drawings, and assembly instructions. * Support suppliers and production teams, including first-article approval, root-cause analysis, and continuous improvement.Prototyping & Testing * Oversee build and test of mechanical prototypes. * Support environmental and reliability testing (thermal cycling, humidity, vibration, thermal shock, drop tests). * Work with test engineering to develop automated or manual test jigs.Required Skills & Experience * Bachelor’s or Master’s degree in Mechanical Engineering (or equivalent). * Strong 3D CAD skills (SolidWorks preferred). * Experience in designing high precision mechanical assemblies. * Strong understanding of manufacturing processes and materials (ideally CNC machining of aluminium alloys). * Hands-on experience with FEA tools (SolidWorks Simulation + Flow preferred) * Excellent understanding of GD&T and engineering drawing standards. * Ability to work closely in cross-functional engineering teams. * Experience with PDM/PLM systems and ECO/ECN release processes.Desirable SkillsExperience with mmWave or RF product development (waveguides, filters, amplifiers).Familiarity with PCB design constraints, RF shielding, and EMI/EMC considerations.Knowledge of high-volume manufacturing and high-reliability design (defence, space, telecoms).Knowledge of RoHS and WEEE compliance.Experience with thermal management of electronics.Knowledge of reliability engineering and qualification standards (MIL-STD).Soft SkillsStrong problem-solving skills and attention to detail.Ability to manage multiple projects and deadlines.Effective communication skills for cross-functional teamwork and supplier interactions.Self-driven attitude with a willingness to learn new tools and processes