Senior Composites Design Engineer

Engineering | Permanent | Rugeley, Staffordshire, WS15 1UZ, UK

Strictly no Agencies or Recruitment Agents

26 Apr 2023


Hill Helicopters has captured a 56% market share of the global light helicopter market with its HX50 5-seat, modern, high-performance, turbine powered, aircraft which is delivering a reboot of the stagnant general aviation market. HX50 is powered by our own GT50, 500hp twin-shaft turboshaft engine, designed, developed and entirely manufactured by Hill, in Staffordshire in the UK. Hill is a vertically integrated manufacturer meaning that all manufacturing is carried in-house by us in our state-of-art modern manufacturing facilities.

Hill is exceptionally well financed, has sold over 800 aircraft in 56 countries over the last two years, and has an order book of over £320M and growing.

As our business grows, we are seeking a capable, amenable & self-motivated senior composites engineers to join our team and drive our current and future aircraft programmes forward, sharing in our success.

Hill Helicopters has developed a ‘Skunk Works’ type approach to aircraft and engine development, that cuts out the viscosity and bureaucracy of big-company, aerospace development and production. By so doing we are delivering world-class new products to market faster, and at a game-changing price-point, which has generated unparalleled aircraft sales & growth.

This is an opportunity, to be in at the ground floor, with a new British aircraft and aero-engine manufacturer, that can deliver levels of professional fulfilment, development and financial rewards & security simply unmatched by any other business in the sector, particularly the large OEM’s.

Key qualifications

    • BSc/BEng in Mechanical or Aerospace Engineering (or equivalent experience)
    • 5+ years of relevant composite design, analysis & development experience
    • Proficient in modelling parts & assemblies in 3D CAD (ideally, but not essential CATIA V5 or CREO, training provided)
    • Proficient in carrying out engineering calculations and the use of modelling and simulations software. (Mathcad, Hypermesh, Optistruct or ANSYS)
    • Experience of aircraft composite structures a major advantage. Experience in developing composite parts from concept to reality.


The successful candidate will work within the composites development team and be responsible for the concept development, scoping and detailed analysis and detailed design of various composite structures of the HX50 aircraft, including:

    • Working with the Chief Composites Engineer and technical specialists to develop composite design schemes and detailed designs for the fuselage structure, doors, cowls, crashworthy seats, and rotor blades.
    • Taking end-to-end responsibility for the development of major composite elements including delivering performance, mass & certification objectives.
    • Carry out the design and development of systems such as fuselage structure, tail boom structure, horizontal stabilizer, rotor blades, seat structures, fairings and cowls.
    • Work effectively and supportively with other aircraft teams to detail system interfaces and ensure cross-team cooperation.
    • Carry out concept development for structural designs, metallic inserts, bonded assemblies, patterns and tooling.
    • Ability to use 3D CAD to develop design concepts with complex shapes and a-surface data.
    • Employ extensive process knowledge to develop part and assembly designs that can be efficiently and cost-effective manufactured.
    • Using hand calculations, simulation methods, modelling tools and CAE tools to size, analyse and optimise system elements.
    • Develop part and system testing plans.
    • Support in-house prototype build.
    • Develop test rigs and carry out system testing.
    • Design systems to meet the certification requirements.
    • Work closely with design staff, technical specialists & production staff.
    • Prepare design and certification documentation.

Our Company

The Hill Group is a privately owned engineering organisation developing and manufacturing both the HX50 Light Helicopter and the GT50 Gas Turbine Engine. We are a pioneering aerospace manufacturer disrupting the market with our ground-breaking new aircraft and modern vertically integrated approach to development & manufacturing. Every element of the HX50 and GT50 are designed and manufactured by us, in-house, at our production facility in Rugeley, Staffordshire, UK.

We employ a fantastically talented, motivated and driven team of professionals. Working as a close- knit flat management structure, we share a common vision for the future of general aviation and a passion to deliver HX50 to our hundreds of global customers.

Hill is currently offering appropriately qualified and suitable individuals the opportunity to become a crucial part of our team developing, industrialising and supporting HX50 & GT50. Few, if any, organisations can provide the levels of professional fulfilment offered by such an exciting, fast-paced and game-changing aircraft development programme and our refreshing new approach to manufacturing. Furthermore, with such a fast-growing organisation, the only limit to your professional development and growth within our company is your own drive and ambition.

We are looking for the people with whom to build our future and we’re ready to invest in you.

Our Industry

General Aviation is the sector of the aerospace industry that produces and operates light aircraft. Since the early 1980’s investment in new product development across the sector has been poor and today the market lacks products that truly meet the expectations of modern owner-operators. Hill is revolutionising the General Aviation market with our new HX50 Helicopter, which combines ‘supercar’ appearance, with unparalleled levels of performance and cost-effectiveness.

Salary range

Generous Salary + Benefits


Be part of the team shaping the future
of general aviation
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Exterior Concept

Interior Concept

GT50 Turbine Engine

General Aviation 2.0

Hill Digital Cockpit

Journey to HX50

Technical Details

Range Simulator



Hill Helicopters
Unit 3, Shackleton Way
Stafford, ST16 1GY
United Kingdom

General Enquiries:
+44 (0) 1384 590700
+44 (0) 1384 590700
+44 (0)1889 228040