Rotor Systems Engineer

Location: Frome, Somerset

Salary: £55,000 - £65,000 depending on experience

Working pattern: 9-day fortnight, averaging 37.5 hours per week

Certo is looking for an experienced Lead Rotor System CAE Engineer to take technical ownership of the mechanical performance and development of a key rotor head assembly within its rotor system design team.

This is a hands-on engineering R&D role combining advanced structural Computer-Aided Engineering (CAE), mechanical design, aerodynamic analysis, physical testing and technical leadership.

Working within a small, established design office, you will play a key role in developing next-generation rotor systems
, taking complex mechanical assemblies from concept through detailed design, simulation, physical validation and certification support.

You will lead engineering analysis and validation activities, establish and improve CAE methods, mentor other engineers and work closely with manufacturing teams, suppliers and test engineers to deliver safe, reliable and high-performance aerospace systems.

• Take full technical ownership of the rotor head system, leading its development from initial concept through detailed design, analysis, testing and certification support.
• Develop and manage the Design Verification Plan (DVP), covering simulation, test mules, test rigs, prototypes and production release.
• Apply first-principles calculations and mathematical modelling to determine initial loads, degrees of freedom, system layouts and component sizing.
• Develop aircraft and system load cases, requirements and acceptance criteria, ensuring requirements flow down to individual components.
• Apply a V-model systems development approach, connecting project definition and engineering development with physical validation.
• Perform detailed structural analysis of complex mechanical systems using industry-standard aerospace FEA solvers.
• Carry out linear and nonlinear stress analysis, aeroelastic loading, structural dynamics, frequency response analysis, fatigue and life calculations.
• Support multidisciplinary CAE activities, including multibody dynamics, aerodynamic loading (CFD), optimisation and advanced analysis methods.
• Develop internal CAE processes, modelling guidelines, solver templates, material models and technical documentation standards.
• Identify opportunities to improve engineering tools, analytical methods and design processes.
• Plan and support physical development testing, including defining test requirements, designing bespoke test rigs and fixtures, and selecting instrumentation.
• Correlate simulation predictions with physical test results, investigate discrepancies and conduct root cause analysis.
• Provide technical leadership to a small team of engineers, offering direction, mentoring and support for professional development.
• Lead formal design reviews and technical risk assessments throughout the product development lifecycle.
• Manage multiple engineering activities against demanding programme schedules.
• Collaborate with manufacturing teams, suppliers and external partners to ensure designs are practical, producible and robust.

• Degree in Aerospace Engineering, Mechanical Engineering or a related discipline.
• Significant experience in aerospace, rotorcraft or complex mechanical systems design.
• Proven experience in the analysis and development of rotor head control assemblies.
• Extensive experience in advanced structural CAE techniques using aerospace-accredited FEA solvers, including coupled mechanical and aerodynamic behaviour.
• Strong analytical skills, with extensive experience in detailed engineering calculations and first-principles problem-solving.

We are looking for an engineer who…