Senior Mechanical Design Engineer - Propulsion & General

Role PurposeAs a Senior Mechanical Design Engineer - Propulsion & General at Manna, you will lead the design, analysis, and integration of mechanical systems for electric propulsion and structural subsystems across our drone platforms. You will work closely with cross-functional teams to optimise performance, thermal management, and system reliability, ensuring designs are lightweight, manufacturable, and efficient. This senior role requires a deep understanding of propulsion mechanics, aerodynamics, vibration analysis, and testing — contributing directly to product innovation and operational excellence.Key ResponsibilitiesLead the design and integration of electric propulsion systems, including motors, ESCs, and propellers.Manage thermal design for propulsion components, including cooling of motors, batteries, and power electronics.Perform aerodynamic and fluid simulations to optimise propeller performance, thrust output, and efficiency.Design lightweight structures using advanced materials such as carbon fibre and composites with focus on vibration damping and structural stability.Conduct system dynamics and vibration (NVH) analysis to ensure rotor balancing, resonance avoidance, and fatigue resistance.Integrate propulsion and energy systems, balancing efficiency, weight, and thermal trade-offs.Plan and execute testing and validation programs — including thrust stands, endurance testing, thermal cycling, and vibration tests.Work cross-functionally with electrical, controls, and avionics teams to ensure seamless propulsion system integration.Apply Design for Manufacturing and Assembly (DFM/DFA) principles to ensure production readiness and scalability.Mentor junior engineers and contribute to knowledge sharing within the mechanical design team.Skills & EducationBachelor's or Master's degree in Mechanical, Aerospace, or Mechatronic Engineering (or related field).7+ years of experience in mechanical design, with a focus on propulsion systems or aerostructures.Strong understanding of electric propulsion integration, including motors, ESCs, and propellers.Proficiency in CAD, FEA, and CFD tools for mechanical and aerodynamic analysis.Experience with thermal management of motors, batteries, and power electronics.Knowledge of lightweight materials (carbon fibre, composites) and structural optimisation methods.Expertise in system dynamics, vibration analysis, and NVH design principles.Experience designing and executing mechanical testing and validation programsStrong analytical, problem-solving, and project management skillsExcellent collaboration and communication skills across multidisciplinary teams.