Product Design Engineer

Description:

Race Anywhere is seeking a talented and detail-oriented Product Design Engineer to lead the full design cycle of innovative mechanical products from concept to production. This hybrid position in Daventry offers the opportunity to work closely with the Founder/CEO to design, prototype, test, and refine products that meet market and customer requirements, while ensuring strength, ergonomics, cost-effectiveness, and durability.

The ideal candidate will be responsible for end-to-end design processes including creating CAD models using Fusion 360, performing basic finite element analysis (FEA), prototyping with 3D printing and CNC/sheet-metal samples, and validating designs through rigorous bench tests and durability cycles. They will collaborate with suppliers for manufacturing, conduct tolerance stack-ups, select suitable materials and fasteners, and ensure seamless production hand-off with comprehensive documentation.

This role is ideal for a hands-on engineer who thrives in a fast-paced, innovative environment and has a passion for mechanical design, quality improvements, and continuous product enhancement.

Key Responsibilities:

• Own the complete product design lifecycle: from initial brief and concept development to CAD modeling, prototyping, and production hand-off.

• Conduct design-for-manufacture (DFM) and design-for-assembly (DFA) processes.

• Perform basic FEA (static and fatigue) and tolerance analysis to ensure product strength and longevity.

• Prototype rapidly using 3D printing, CNC, and sheet metal techniques.

• Validate product designs with bench tests, load/torque/slip analysis, vibration and durability testing.

• Produce detailed technical documentation: GD&T drawings, costed BOMs, and assembly instructions.

• Collaborate with suppliers on tooling, finishes, and continuous quality improvement.

• Support production through first-article approval, engineering change notices (ECNs), and warranty issue resolutions.

Qualifications & Skills:

• 2–5 years of product or mechanical design experience (consumer hardware, sports, automotive, or related industries).

• Proficiency in Fusion 360 (CAD/FEA) with strong skills in assemblies, joints, and configurations.

• Knowledge of GD&T, tolerance stack-ups, and mechanical fasteners.

• Familiarity with manufacturing processes: aluminium extrusions, sheet metal, CNC, injection-moulded plastics, casting, coatings, and finishes.

• Hands-on prototyping and testing expertise.

• Nice-to-have: jigs/fixtures design, supplier collaboration, cost reduction, and process automation experience (Make.com).

Success Milestones (First 90 Days):

• Deliver 1–2 new product concepts through prototype and testing phases.

• Update design standards for fasteners, threads, finishes, and torque specifications.

• Produce a supplier-ready drawing pack and costed BOM for at least one production part.

• Resolve at least one quality/warranty issue with an engineered solution.

Tools You Will Use:

• Fusion 360 (CAD/FEA)

• Microsoft Suite

• 3D printing tools and prototyping equipment

• Test rigs, calipers, torque tools

• BOM/PLM sheets and internal support systems