Mechanical Designer & FEA Analysis

Mechanical Designer & FEA Analysis
Impact a better future

At Serco, we bring together the right people, technology, and partners to deliver innovative solutions that impact a better future.

We have been operating in the Middle East since 1947 and have a profound understanding of the region.

With over 4,500 colleagues here, we support governments across defence, space, transport, emergency services, justice and migration, and other vital public services. Our core capabilities span service design and advisory, customer experience, complex programme management, systems integration, and asset and facilities management, alongside environmental and case management services.

Guided by our unique service model, we work together with clients and partners to achieve long-term visions and tackle some of the world’s most complex challenges.

 
Your Opportunity  

The Mechanical Designer & FEA Analysis role is responsible for the design, analysis, verification, and documentation of aerospace structures, propulsion hardware, test articles, and supporting ground systems. This role blends advanced mechanical design capability with strong analytical skills to ensure components are lightweight, manufacturable, structurally sound, and compliant with aerospace requirements. The position involves creating detailed CAD models and drawings, performing finite element simulations, preparing technical documentation, and collaborating closely with manufacturing, testing, and integration teams throughout the development lifecycle.

Key Accountabilities

Mechanical Design for Aerospace Structures

• Develop mechanical designs for aerospace structures, propulsion systems, test articles, ground support equipment and related hardware. Prepare 3D CAD models, assemblies and detailed engineering drawings.

• Support the design of lightweight, manufacturable and structurally efficient components. Ensure mechanical designs meet functional, structural, interface and integration requirements.

Finite Element Analysis and Structural Simulation

• Perform FEA simulations to assess stress, deformation, stiffness, buckling, modal response and structural margins. Define appropriate boundary conditions, loads, constraints and material models for aerospace applications.

• Prepare clear FEA reports including assumptions, methodology, results, margins of safety and recommendations.

Manufacturing, Tolerancing and Drawing Preparation 

• Prepare manufacturing drawings with appropriate dimensions, tolerances, GD&T, surface finish, materials and inspection requirements. Ensure designs are suitable for machining, fabrication, welding, and assembly processes as applicable.

• Apply tolerance stack-up principles to ensure proper fit, alignment and assembly of aerospace components. Coordinate with manufacturing teams and vendors to resolve design-for-manufacturing issues.

Design Verification and Technical Documentation

• Support verification of mechanical designs against requirements, standards and test conditions. Prepare technical documentation including design reports, analysis reports, interface control documents, BOMs and assembly instructions.

• Support design reviews including concept reviews, PDR, CDR and manufacturing readiness reviews. Ensure traceability between requirements, design decisions, analysis results and final drawings.

Coordination with Manufacturing, Testing and Integration Teams

• Work closely with propulsion, structures, simulation, manufacturing, instrumentation and test teams. Support test article preparation, assembly, integration and troubleshooting.

• Coordinate with external suppliers and internal stakeholders to ensure technical requirements are understood and implemented.

Specific Requirements

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, or a related field, with 3–7 years of relevant experience in mechanical design and structural analysis.

• Strong proficiency in 3D CAD modelling, assembly design, and preparation of manufacturing drawings for aerospace or high-performance engineering hardware.

• Practical experience performing FEA for metallic and/or composite structures, including static, vibration, buckling, thermal, or pressure load cases.

• Good understanding of manufacturing processes, tolerancing, GD&T, tolerance stack-up, materials, fasteners, joints, and design for manufacturing.

• Ability to prepare clear technical documentation, including design reports, FEA reports, BOMs, interface documents, and drawing packages.

• Experience supporting design reviews, prototype manufacturing, integration, testing, and correlation of analysis results with test data.

Join Us 

At Serco, we believe there is a place here for everyone. A place where you can bring your authentic self to work every day. Our workplace culture is one that embraces diversity and fosters equity, respect, and belonging for every individual. We are committed to equal employment opportunities and creating an inclusive environment that proudly celebrates the perspectives and backgrounds that each of our employees bring to work every day. 

Join Serco and be part of a values-driven organization that invests in the development and well-being of its employees and offers a rewarding and fulfilling career.

Serco is committed to Equal Employment Opportunities and is committed to ensuring the safety of all of its employees through its Zero Harm initiative. Please visit careers.serco.com for more information.