Aerial Installation jobs in Cranleigh

Prismatic is a technology development company, specialising in the design, manufacture and delivery of innovative, high value aerospace products and systems. Prismatic is a subsidiary of BAE systems, led by a technically and commercially focused team. Our cutting-edge systems (such as the high-altitude PHASA-35) have clear commercial value, are developed at pace and address critical customer needs.

We are seeking a Battery Design and Integration Engineer to join our growing team working on exciting new Unmanned Air Vehicles (UAVs). In this role, you will take ownership of the architecture, mechanical packaging, and full-system integration of advanced energy storage systems for cutting-edge unmanned aerial platforms. You will play a key role in defining next-generation battery architectures for HAPS applications including high-energy-density, lightweight modules for electric and hybrid-electric propulsion technologies. This is an exciting opportunity to directly shape the future of autonomous aviation, energy-efficient flight, and long-endurance mission capabilities.

Tasks and Accountabilities

• Pouch Pack Architecture & Design: Lead the mechanical, electrical, and thermal design of custom modules and packs, prioritizing structural constraints like cell swelling, stack pressure management, cell characterisation and critical SWaP (Size, Weight, and Power) constraints.

• System Integration: Oversee the seamless physical and electrical integration of battery storage systems into the UAV platform, ensuring compatibility with the wider system, BMS, and electric propulsion systems.

• Thermal & Safety Management: Design and analyse module-level thermal management solutions to prevent thermal runaway propagation, manage heat dissipation during discharge/charge cycles, and ensure safety during high-altitude operations.

• Requirements & Validation: Generate integrated requirements and test strategies (functional, integrity, and performance) specifically for pouch cells, modules, packs, and management software.

• Testing & HIL Evaluation: Assist the test and evaluation of battery systems at unit levels up to full Hardware-in-the-Loop (HIL) system integration.

• Flight Trials Support: Deploy on Flight Trials to lead and support battery installation, pre-flight health monitoring, and live system testing as required.

• Data Analysis & Fault Finding: Analyse test data, map battery charge/discharge profiles, and lead problem-solving/fault-finding for energy storage systems at both unit and platform levels.

• Closely work with technical suppliers and vendors to source specialized materials, evaluate manufacturing feasibility, and co-develop solutions to drive technical innovation. Accountable for fostering strong, collaborative supplier relationships to optimize product performance, and maintain project schedules.

• Design for Manufacture (DFM): Generate assembly documentation, internal quality standards, and assembly processes including cell constraints to assist manufacturing teams with the battery pack build.

Qualifications and Experience

Essential:

• Education: Degree in Aerospace, Mechanical, Electrical, or Mechatronic Engineering (or equivalent experience).

• Industry Experience: At least 3 years of proven industry experience, with a core focus on battery pack design, energy storage systems, or cell integration.

• Pouch Cell Expertise: Strong understanding of pouch-cell-specific design challenges, including cell retention, expansion/swelling allowances, thermal dissipation paths, and high-integrity tab termination (e.g., laser/ultrasonic welding).

• UAV/Aerospace Context: Strong understanding of battery system integration within the aircraft or UAV domain (ideally HALE, eVTOL, or high-performance Automotive).

• Battery Characteristics: Deep technical understanding of energy storage chemistries (e.g., high-density Li-ion, Li-Sulfur, or solid-state pouch formats) and complete mastery of battery charge/discharge characteristics, cell balancing, and degradation.

• SWaP Constraints: Proven experience navigating UAV-specific challenges, including extreme mass optimization, volume limitations, and harsh environmental conditions.

• Manufacturing & Supply Chain: Strong Design for Manufacture (DFM) experience for high-integrity electronics/hardware, with the ability to manage third-party cell suppliers and manufacturing vendors.

• Project Autonomy: Ability to independently manage packages of work, directing technicians and suppliers to meet strict programme timescales.

Desirable:

• Propulsion Integration: Hands-on experience integrating high-voltage battery packs with electric propulsion systems for UAVs or eVTOL platforms.

• Simulation & Modelling: Proficient in modelling battery cell behaviour, thermal dissipation, or state-of-charge (SoC) algorithms using MATLAB, Python, or thermal CFD tools (TAITherm).

• Compliance & Safety: Familiarity with aerospace safety, certification principles, and battery standards (e.g., DO-311A, Def Stan 00-970, STANAGs, DO-160, or ARP4754A).

• Novel R&D: Experience working within cutting-edge R&D programs developing large-scale or complex unmanned vehicles.

• Regulatory Frameworks: Familiarity with UAV certification frameworks (e.g., CAP722, EASA SC-Light UAS, MAA regulations).

• Professional Status: Chartered Engineer (CEng) or working towards professional registration.

What We Offer

We’re proud to offer a competitive package and a range of benefits designed to support your career and wellbeing, including:

• Location: Alton (Hampshire), UK.

• Contract: Permanent, 37.5 hours per week (excluding breaks). Hybrid working (where applicable), giving you the flexibility to balance time between home and our offices (norm is 3 days a week).

• Salary: £45,000-£50,000 – dependent on experience.

• Bonus: Non contractual company performance related bonus.

• Pension: 10% company contribution

• Green Benefits: Access to our Green Car/EV scheme via salary exchange.

• Annual Leave: 25 days plus bank holidays (rising to 28 days after 3 years’ service).

• Employee Schemes: Eligibility for the Company Share Incentive Scheme, Company Performance Free Share awards, Cycle to Work scheme, and a Halfords Trade Discount Card.

• Community & Culture: Social and employee engagement activities through our Prismatic Pulse group.

• Wellbeing: Access to Occupational Health support, including an Employee Assistance Programme (EAP).

Inclusion

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 team and is vital to the work we do.

Proud to Support the Armed Forces Community

We are proud signatories of the Armed Forces Covenant and holders of the Bronze Award, demonstrating our commitment to supporting those who serve and have served.

We recognise that the discipline, teamwork, problem-solving skills, and resilience gained through military life are a huge asset to our organisation. That’s why we actively encourage applications from veterans, reservists, and the partners and families of those serving. If you’ve served in any capacity, or supported someone who has, we’d love to hear from you.