Senior Battery Design Engineer

Join the Team Building the Future of Flight

Are you looking for an opportunity to make a real impact, take on exciting challenges, and be part of a team that's shaping the future of aviation?

At Malloy Aeronautics, you'll play a key role in helping us develop innovative technology that's changing the way the world moves.

Who are we?

We're on a mission to revolutionise unmanned flight. At Malloy Aeronautics, we develop advanced heavy-lift UAVs for both defence and commercial applications.

What sets us apart is our in-house approach. From design and engineering to manufacturing and testing, the majority of our work happens under one roof in Berkshire, allowing us to innovate quickly, maintain exceptional quality, and bring ideas to life faster.

For our teams, that means hands-on involvement, real ownership, and the opportunity to help shape the future of aviation.

What are we looking for?

Malloy Aeronautics are looking for an engineer with experience working with pouch cell integration to join our concept development team. This role will focus on the development of batteries from a set of requirements to production product. This role suits an engineer who has a broad skillset across battery design elements and enjoys spending time hands-on building and testing.

Ability to hold Security Clearance – 5 years residence in the UK

What You’ll Be Doing (but Not Limited To)

Leading the physical design of Malloy’s battery platforms developing packs from a concept stage to production.

Interface with other engineering groups on collaborative projects to deconflict integration issues and execute against project plans.

Developing test and validation plans for battery packs, and analysing test data to refine pack design

Developing prototype and/or concept battery packs with novel technologies

Working with and supporting suppliers to ensure parts are on time and designed to best suit their needs.

Generating technical documentation, reports, and supporting build guide development

Essential Skills And Experiences

Relevant degree in engineering

Prior in-depth experience in battery pack design and cell integration.

Experience using, designing, integrating and packaging pouch cells.

Experience with battery thermal management methodologies.

Knowledge of cell connection methodologies including laser welding.

Experience with a wide variety of production processes including but not limited to lathe, 3-5 axis machining, water jet, laser cut, punch, bending, welding, casting, various 3d printing types and injection moulding.

Experience using CAD software, ideally SolidWorks.

Experience designing for high voltage applications and relevant practical high voltage training (preferably SAP/level 3)

Knowledge of project lifecycle management, developing requirements, and working in a gated design environment.

Desired Skills And Experiences

Experience in high-performance and/or high pack factor battery applications such as motorsport, aerospace, etc.

Electrochemical knowledge & experience in lab environment

Pack simulation using FEA/CFD packages (thermals, electrical simulation, vibration etc.)

Experience working with mass critical systems

Experience with high vibration applications

Familiarity with text-based programming

Knowledge of battery testing standards

Benefits You May Be Eligible For

Alternate Fridays off with our 9-day fortnight

BAE Systems Share Incentive Plan

5% employer pension contribution

Annual collective incentive bonus scheme

Enhanced family leave with 6 months' full-pay maternity leave and 4 weeks' full-pay paternity leave

20 days' annual leave, increasing with service, plus a 3-day Christmas shutdown

Company sick pay

Healthcare Cash Plan with Virtual GP access, dental and optical support, plus free cover for dependent children up to age 24

Mental health and wellbeing support available 24/7

Cycle to Work Scheme

Proud supporter of the Armed Forces through our Bronze Armed Forces Covenant commitment.

Malloy Aeronautics employees will be subject to both security and export control restrictions. These restrictions mean that factors including your nationality, any previous nationalities you have held, and your place of birth may limit those roles you can perform for the organisation.

We’re committed to building an inclusive workplace where everyone feels valued and supported. We know that a diversity of backgrounds, perspectives and experiences strengthens our teams and is vital to the work we do.

Please be aware that many roles at Malloy Aeronautics are subject to both security and export control restrictions. These restrictions mean that factors such as your nationality, any nationalities you may have previously held, and your place of birth can restrict the roles you are eligible to perform within the organisation. All applicants must as a minimum achieve Baseline Personnel Security Standard. Many roles also require higher levels of National Security Vetting where applicants must typically have 5 to 10 years of continuous residency in the UK depending on the vetting level required for the role, to allow for meaningful security