Principal Mechanical Design Engineer

Principal Mechanical Design Engineer

Bicester, Oxfordshire
Permanent

As the Principal Mechanical Design Engineer, you will be responsible for the development of all physical components within our advanced charging systems. This encompasses primary and secondary structures, control panels, high-voltage (HV) and low-voltage (LV) sub-systems, wiring harnesses, and thermal management systems. This hands-on leadership role involves defining architecture, developing mechanical frameworks, and steering the transition to full-scale production.

In this role, you will take ownership of the design and release process for our high-performance charging systems, aligning with our strategic roadmap. You will be instrumental in shaping the certification process and ensuring design-for-manufacture principles are met while maintaining critical quality, cost, functionality, weight, and timing targets. Responsibilities will also include testing and validation of physical systems, such as high-voltage batteries, grid-connected AC-DC units, and high-power DC charging infrastructure.

A good understanding of electric vehicle (EV) / charging infrastructure and associated technologies is required for this role. Additionally, you must possess a balanced blend of mechanical design expertise and product/industrial design knowledge to drive the development of high-quality, user-centric products. This cross-disciplinary approach will ensure our products are not only mechanically sound but also aligned with practical and aesthetic design principles for end-user satisfaction.

This is an exceptional opportunity to drive the development, testing, and validation of a core product within a fast-growing, dynamic company. The ideal candidate will have a solid background in mechanical and design engineering, with substantial experience in electric vehicle (EV) technologies, including structural components, cooling systems, battery integration, and charging hardware. A hands-on approach is essential, along with the ability to develop innovative concepts and support system assembly on the production line.

Responsibilities

• Lead the design and development of mechanical systems, products, and components, developing and validating engineering designs.
• Ensure product performance meets key engineering targets through rigorous validation.
• Design and integrate cooling and heating systems for EV and power electronics.
• Select materials and components, producing detailed CAD drawings.
• Develop and maintain system and component-level DFMEAs.
• Own and run the in-house build & test lab.
• Prototype designs to support product verification and market entry strategies.
• Conduct feasibility assessments and cost-benefit analyses to ensure design viability.
• Identify and resolve design and manufacturing challenges using CAD and analytical tools.
• Interpret and adhere to regulatory requirements, defining appropriate testing strategies.
• Deliver concept schemes, final designs, and release drawings in line with project goals.
• Drive continuous and iterative improvement across the product function.
• Lead change management initiatives, root cause analyses, and corrective actions.
• Manage Design Verification Plan & Report schedules to ensure compliance and certification.
• Provide technical mentorship to technicians and support production processes.
• Oversee engineering release processes from concept to finalized documentation.
• Manage supplier, partner & industry engagement.
• Assist in creating RFQ/RFI documentation and support supplier interactions.
• Work closely with suppliers to refine cost, manufacturability, and design quality.
• Stay informed about industry standards, regulations, and emerging technologies.

Qualifications

Must-haves

• MEng degree in mechanical, electrical, or automotive engineering.
• Minimum of five years’ experience in the mobility sector (automotive, charging, battery, or EVs).
• Good experience with EV /charging infrastructure, including AC-DC units, high-power DC charging, and associated systems.
• Proven capability in both mechanical design and product/industrial design processes, ensuring products are optimized for function, usability, and visual appeal.
• Experience with mechanical and electrical EV components, including CAN protocol.
• Strong knowledge of battery technologies, including cell chemistries and BMS systems.
• Proficiency in CAD software.
• Expertise in materials, pressings, and volume manufacturing techniques.
• Experience in structural analysis (stress, stiffness, fatigue, optimization).
• Ability to analyze test data and correlate with simulation results.
• Understanding of battery characteristics, thermal systems, and pack cooling.
• Strong foundation in fluid mechanics and heat transfer principles.
• Comprehensive knowledge of GD&T, drawing standards, and assembly documentation.
• Familiarity with safe handling of HV systems and regulatory compliance.
• Experience with system/component delivery, including FMEA, quality planning, and PPAP.
• Ability to work independently in a dynamic, process-light environment.
• Hybrid work model (minimum 3 days on-site in Bicester).
• Self-motivated, collaborative, and a strong team player.
• Eligible to work in the UK.

Nice-to-haves

• Experience working with EV charging or Battery Energy Storage systems.
• Knowledge of fleet vehicle (eLCV and eHGV) technologies is advantageous.
• Ability to challenge experts, consultants, and seniors by presenting a measured systematic first-principles approach.
• Strong understanding of EV charging standards and protocols.

To apply for the role, please share your CV with us for our review at:
📧 gemmaf@gahl.co.uk