LiveLink Aerospace is seeking a Senior UAV Design Engineer to own the lifecycle of UAV systems from concept through production. The role involves mechanical design, rapid prototyping, systems integration, and field testing of unmanned aerial vehicles. You will work hands-on with hardware and collaborate with cross-functional teams to bring prototypes to low-volume manufacturing.

Responsibilities

Mechanical & Structural Design: Design high-performance UAV airframes, payload structures, and mechanical assemblies using Fusion 360. Develop detailed CAD models and production-ready technical drawings.
Component Specification: Select and specify optimal UAV components, including propulsion systems, motors, ESCs, batteries, telemetry modules, sensors, and flight controllers.
Rapid Prototyping: Design and rapidly iterate prototypes utilising 3D printing, sheet metal, laser CNC, and other advanced manufacturing methods to optimise performance and manufacturability.
Manufacturing & Documentation: Produce comprehensive assembly drawings, Bills of Materials (BOMs), and detailed build instructions to ensure seamless knowledge transfer and traceability for production teams.
Systems Integration & Testing: Perform hands-on integration, wiring, and soldering of electronics. Configure, tune, and troubleshoot flight stacks running Betaflight and ArduCopter firmware.
Field Operations & Validation: Conduct field testing and flight validation. Debug UAV performance issues under real-world conditions, identifying root causes to drive iterative design improvements.
Cross-Functional Collaboration: Partner closely with RF and software engineers to ensure hardware accommodates system requirements, and collaborate with production teams to transition prototypes into scalable, low-volume manufacturing workflows.
Vendor Management: Coordinate with external suppliers and manufacturers for prototype fabrication and low-volume production runs.

Requirements

Advanced proficiency in parametric CAD (Fusion 360) and technical drawing creation.
Deep understanding of UAV architecture, system integration, and weight/balance optimization.
Hands-on experience with additive manufacturing (3D printing), sheet metal design/fabrication, laser cutting, and CNC bending machinery.
Strong practical skills in electronics assembly, routing, and precision soldering.
Proven experience configuring and tuning ArduCopter and Betaflight flight stacks.
Excellent field troubleshooting, debugging, and data-logging analysis skills.
A proactive problem-solver who thrives in rapid development cycles.
Strong collaborative communication skills for working alongside multidisciplinary engineering teams.
Excellent organisational skills for managing BOMs, suppliers, and technical documentation.

Nice to have

GVC (General Visual Line of Sight Certificate) certification for operating multirotor and fixed-wing UAV platforms is highly desirable.