Sr. Mechanical Design Engineer - (UAV Research & Development)
Job Fit Check
Base Career helps you apply smarter for this job.
Key skills for this role
About the Role
A confidential company in Abu Dhabi seeks a Senior Mechanical Design Engineer for UAV R&D. The role involves structural design, FEA, material selection, and prototyping of next-generation UAV platforms.
Key Skills for This Role
Responsibilities
- Conceptualize and design primary airframe structures, component layouts, and mechanical subsystems for large scale UAVs and robotic platforms using advanced 3D CAD software
- Select and design with advanced materials, focusing on carbon fiber composites, aerospace grade aluminum, and additive manufacturing technologies
- Design robust internal mounting structures, rugged environmental enclosures, and deployment mechanisms for payloads, sensors, avionics, and power plants
- Perform static, dynamic, and modal Finite Element Analysis (FEA) to validate structural integrity and optimize designs
- Apply DFM/DFA principles to ensure components can be reliably fabricated via CNC machining, composite molding, or 3D printing
- Work directly with the workshop team to fabricate, assemble, and modify mechanical prototypes
- Participate in flight test campaigns to evaluate mechanical reliability under real world conditions
Requirements
- Bachelor’s degree or equivalent in Mechanical Engineering, Aerospace Engineering, Mechatronics, or related field
- Minimum of 5 years of professional experience in mechanical product design, specifically focused on UAV platforms, aerospace structures, or complex mobile robotic systems
- Proven track record contributing to defense industry or heavy industrial UAV projects, preferably involving fixed wing or multirotor aircraft above 20kg MTOW
- Advanced proficiency in professional 3D CAD suites (e.g., SolidWorks, CATIA, or Siemens NX) with strong command of complex surface modeling and assembly management
- Demonstrated experience utilizing FEA tools (e.g., ANSYS, SolidWorks Simulation, or Altair HyperMesh) for structural, thermal, and vibration analysis
- Deep understanding of composite manufacturing processes, precision CNC machining, sheet metal fabrication, and GD&T, DFMEA
- Familiarity with designing for harsh environments, including ingress protection (IP ratings), thermal management, and vibration/shock isolation
- Willingness to support outdoor field testing and collaborate across disciplines
Full Job Posting
Role Overview
- As a Research and Development Engineer (Mechanical Design), you will be responsible for the structural design, analysis, and mechanical integration of next generation UAV platforms and robotic systems.
- You will lead the development of airframes, enclosures, and deployment mechanisms from initial concept through to physical prototyping.
- Working closely with aerodynamicists, materials specialists, and electronics teams, you will ensure that our platforms are lightweight, structurally optimized, and rugged enough to withstand demanding operational environments.
- This role bridges advanced CAD engineering with hands on workshop prototyping and field test validation.
Key Responsibilities
- Structural & Airframe Design: Conceptualize and design primary airframe structures, component layouts, and mechanical subsystems for large scale UAVs and robotic platforms using advanced 3D CAD software.
- Material Selection & Optimization: Select and design with advanced materials, focusing heavily on carbon fiber composites, aerospace grade aluminum, and additive manufacturing (3D printing) technologies to maximize structural strength to weight ratios.
- Mechanism & Payload Integration: Design robust internal mounting structures, rugged environmental enclosures, and deployment mechanisms for critical payloads, sensors, avionics, and power plants (including electric and turbojet propulsion systems).
- Simulation & Analysis (FEA): Perform static, dynamic, and modal Finite Element Analysis (FEA) to validate structural integrity, analyze stress concentrations, and optimize designs against high vibration and aerodynamic flight loads.
- DFM/DFA Alignment: Apply Design for Manufacturing (DFM) and Design for Assembly (DFA) principles to ensure components can be reliably fabricated via CNC machining, composite molding, or 3D printing.
- Prototyping & Assembly Collaboration: Work directly with the workshop team to fabricate, assemble, and modify mechanical prototypes, resolving tolerance stackups and physical integration challenges on the fly.
- Field Test Support: Participate in flight test campaigns to evaluate mechanical reliability under real world conditions, analyzing structural wear, vibration data, and landing impacts to drive iterative design improvements.
Required Qualifications
- Education: Bachelor’s degree or equivalent in Mechanical Engineering, Aerospace Engineering, Mechatronics, or a highly related technical field.
- Experience: Minimum of 5 years of professional experience in mechanical product design, specifically focused on UAV platforms, aerospace structures, or complex mobile robotic systems.
- UAV Scale Familiarity: Proven track record contributing to defense industry or heavy industrial UAV projects, preferably involving fixed wing or multirotor aircraft above 20kg Maximum Takeoff Weight (MTOW).
- CAD Expertise: Advanced proficiency in professional 3D CAD suites (e.g., SolidWorks, CATIA, or Siemens NX) with a strong command of complex surface modeling and assembly management.
- CAE Capabilities (preferable): Demonstrated experience utilizing FEA tools (e.g., ANSYS, SolidWorks Simulation, or Altair HyperMesh) for structural, thermal, and vibration analysis.
- Manufacturing Knowledge: Deep understanding of composite manufacturing processes, precision CNC machining, sheet metal fabrication, and geometric dimensioning and tolerancing (GD&T), DFMEA.
- Environmental Ruggedization: Familiarity with designing for harsh environments, including ingress protection (IP ratings), thermal management, and vibration/shock isolation for sensitive electronics.
- Field & Team Agility: Willingness to support outdoor field testing, troubleshoot mechanical assemblies in real world environments, and collaborate seamlessly across hardware, software, and systems engineering disciplines.
Apply for this job in 1 click
Skip the repetitive application forms
Install the Base Career Chrome Extension and autofill job applications across major job boards with your profile.
Trusted by over 500,000 job seekers on Base Career
More from this employer
More jobs at Confidential Company
Product Graphic Designer
Sharjah, UAE
Confidential Company seeks a Senior Product Graphic Designer to create packaging, labels, brochures, digital content, and POS materials. The role requires collaboration with cross-functional teams and managing multiple d
Senior QAQC Engineer
Dubai, UAE
The employer is seeking a Senior QAQC Engineer with experience in civil construction projects in UAE. The role involves developing and implementing QAQC plans, conducting inspections and audits, leading root cause analys
Sales Manager
Riyadh, KSA
The Sales Manager – Fire Protection Systems is responsible for driving sales growth by developing new business opportunities, managing key customer relationships, and achieving ...
Mechanical Maintenance Manager (Deep Drilling)
Hawally, KWT
The Mechanical Maintenance Manager (For Land Drilling Rigs, Associated Equipment’s and Workshop) is responsible and In-Charge for Maintenance department to lead, manage, and opt...
Real Estate Administrator
Sharjah, UAE
Manage property, tenant, and lease records, ensuring all documentation is accurate and up to date. Prepare tenancy agreements, lease renewals, amendments, and termination docume...
Carpenter In-Charge
Sharjah, UAE
The employer is seeking an experienced Carpenter In-Charge to supervise carpentry teams and coordinate daily activities. The role involves inspecting, repairing, and installing wooden structures, reading technical drawin
Farm Supervisor
Dammam/Khobar/Eastern Province, KSA
We are seeking an experienced and dedicated Farm supervisor to oversee the daily operations of a diversified commercial farm specializing in date palm cultivation, greenhouse pr...
Electrical Maintenance Manager (Deep Drilling)
Hawally, KWT
The Electrical Maintenance Manager (For Land Drilling Rigs & Associated Equipment’s and Work Shop) is responsible and In-Charge for planning, managing, and supervising all elect...
Product Graphic Designer
Sharjah, UAE
Senior QAQC Engineer
Dubai, UAE
Sales Manager
Riyadh, KSA
Mechanical Maintenance Manager (Deep Drilling)
Hawally, KWT
Real Estate Administrator
Sharjah, UAE
Carpenter In-Charge
Sharjah, UAE
Farm Supervisor
Dammam/Khobar/Eastern Province, KSA
Electrical Maintenance Manager (Deep Drilling)
Hawally, KWT