Senior Battery Design Engineer

Job title

Senior Battery Integration Engineer

Salary Range

Negotiable

The Malloy Aeronautics Team

Malloy Aeronautics Limited specializes in the development of heavy lift unmanned air vehicles (UAVs) for both civilian and military uses. Located in Berkshire, our operations focus on in‑house design and manufacturing. This vertical integration enables us to control most aircraft components on‑site, supporting innovation and high standards throughout development.

About The Role

Malloy Aeronautics is seeking an engineer with experience in pouch cell integration to join our concept development team. The role focuses on developing batteries from a set of requirements to a production product. It suits an engineer who has a broad skillset across battery design elements and enjoys hands‑on building and testing.

Ability to hold Security Clearance

5 years residence in the UK

What you’ll be doing

• Leading the physical design of Malloy’s battery platforms, developing packs from concept to production.
• Interface with other engineering groups on collaborative projects to resolve 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

• 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 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 or aerospace.
• Electrochemical knowledge & experience in a lab environment.
• Pack simulation using FEA/CFD packages (thermals, electrical simulation, vibration).
• 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

• Working Environment: 9‑day fortnight
• Free parking, free lunch on working Fridays, fruit twice a week, tea and coffee
• Company Pension Scheme
• Discretionary Employee Incentive Bonus Scheme
• Employee Share Incentive Plan
• Company Sick Pay
• Maternity and Paternity enhanced Leave
• Healthcare Cash Plan including Virtual GP, Dental Cover, Vision Cover, Discounted Gym Membership
• 20 days Annual Leave, increasing with long service
• Employee Assistance Programme (24hr Helpline)
• Mental Health First Aiders
• Cycle to Work Scheme
• Casual Dress
• Bronze Level Armed Forces Covenant

Why Malloy Aeronautics?

Our company benefits from a streamlined process where engineering teams are involved in the entire lifecycle of our UAVs—from initial design through production. This fosters faster, more efficient product development. We value professionals with a background in both research and development (R&D) and design for manufacture.

Compliance and Equal Opportunity

Malloy Aeronautics employees will be subject to security and export control restrictions. We are an equal opportunity employer and value diversity in our workforce. If you have a disability or health condition that may affect performance in assessments or interviews, please speak with your recruiter about potential reasonable adjustments.

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