Staff Project Engineer, Electrical Hardware - UK

📋 Description

• • Lead the design and integration of the physical vehicle platform for an electric 2-wheel vehicle, translating product and customer requirements into vehicle-level hardware requirements and design targets.
• • Define subsystem requirements for chassis, frame, mounting structures, suspension, brakes, and high-voltage/low-voltage component packaging to ensure functional and safe vehicle architecture.
• • Support key vehicle architecture decisions including component layout, load path definition, and serviceability considerations across mechanical and electrical systems.
• • Own the CAD design of critical vehicle hardware systems including structural components, mounting systems, and packaging structures using SolidWorks, Creo, CATIA, NX, or equivalent.
• • Develop detailed 3D models, assemblies, and production-ready engineering drawings for prototype and volume manufacturing stages.
• • Manage CAD integration of vehicle hardware with battery, motor, controllers, and harnesses to ensure optimal packaging and system compatibility within the vehicle platform.
• • Drive design for manufacturability, assembly, and serviceability throughout the product lifecycle, balancing ergonomics, cost, and production feasibility.
• • Lead hardware integration of mechanical and electrical systems during prototype builds, vehicle bring-up, and system validation phases.
• • Troubleshoot fit, function, and durability issues during development, implementing design changes based on test feedback and build results.
• • Define and support vehicle-level validation activities including durability, environmental, and functional testing protocols.
• • Analyze test data to identify failure modes and drive design improvements to meet performance and safety targets.
• • Support regulatory and safety compliance testing, ensuring alignment with applicable standards for electric mobility vehicles.
• • Identify vehicle-level risks and failure modes, leading or contributing to DFMEA and vehicle hazard analysis to implement mitigation strategies.
• • Act as the primary technical integrator between mechanical, electrical, firmware, manufacturing, and supplier teams to deliver cohesive vehicle systems.
• • Coordinate cross-functional design reviews, technical trade studies, and program milestones to ensure alignment on project objectives.
• • Maintain accurate design documentation and manage engineering change orders through production ramp-up, quality issue resolution, and field feedback loops.
• • Support manufacturing ramp activities, addressing production quality issues and collaborating with suppliers to ensure component conformity and delivery timelines.
• • Apply expertise in structural design, vibration analysis, and durability considerations to optimize vehicle hardware performance under real-world conditions.
• • Leverage experience with electric motorcycles, scooters, or powersports vehicles to inform design decisions and innovation in small EV platform development.
• • Work hands-on throughout the product development cycle—from initial concept through prototyping, validation, and into volume production—with end-to-end ownership of vehicle hardware integration.