Senior Power Pack Design Engineer
Confirmed on the employer's own hiring board on Oct 31, 2026. First seen by Alion on Oct 29, 2026. NAFFCO scores C on the Alion truth index.
Role purpose
The Senior Power Pack Design Engineer leads the design, development, and optimization of hydraulic power pack systems and their integration with vehicle chassis and related systems. The role translates technical specifications and customer requirements into safe, reliable and manufacturable designs, guiding the work from concept and calculations through drawing release, prototype validation and production support.
Key responsibilities & Job Description
Power pack design and system integration
Develop and optimize hydraulic power pack designs in line with project specifications, customer requirements, operating conditions and applicable standards.
Select and size suitable pumps, motors, reservoirs, filters, coolers, valves, manifolds, piping, instrumentation and other system components.
Prepare and verify engineering calculations, hydraulic schematics, layouts, 3D models, assembly drawings, bills of materials and design specifications.
Finalize the design, performance and integration of the engine, cooling system, transmission, brake system and axles within the chassis, ensuring compatibility across interfaces and operating requirements.
Assess packaging, routing, material selection, access for maintenance, assembly sequence, weight, manufacturability and cost when optimizing the complete system.
Technical leadership and design assurance
Review and approve designs, drawings, calculations and technical specifications prepared by engineers reporting to the role; provide clear technical direction and feedback.
Set and maintain design practices, drawing standards, revision control and engineering checks for assigned projects.
Identify design risks, interface issues and performance constraints early, and coordinate practical engineering solutions with relevant stakeholders.
Prototype, testing and continuous improvement
Oversee prototype build, commissioning and testing; define or support test plans covering performance, durability, reliability and safety.
Review test and field data, investigate failures or non-conformities, and implement design changes based on verified results.
Monitor developments in power pack, hydraulic and vehicle systems technology and apply suitable innovations to improve performance, efficiency, reliability and lifecycle cost.
Project delivery and compliance
Coordinate with product development, manufacturing, procurement, suppliers, quality assurance and other engineering teams to resolve technical matters and support on-time project completion.
Confirm that designs meet applicable industry standards, safety requirements, environmental guidelines, customer specifications and internal engineering procedures.
Prepare and maintain technical documentation, including design reports, calculations, manuals, drawings, test records and change documentation relevant to each project.
Provide regular, concise updates on design progress, risks, resource needs and system performance to the Line Manager and Director.
Technical and professional competencies
Proficiency with 3D CAD and engineering drawing tools; experience with hydraulic design or simulation software is preferred.
Strong understanding of design for manufacture and assembly, tolerance management, materials, failure analysis and product safety.
Ability to interpret customer specifications and applicable engineering standards and convert them into verified design requirements.
Clear technical communication, sound decision-making and effective coordination with internal teams and external suppliers.
Organized approach to managing multiple design activities, engineering changes, documentation and project deadlines.
Qualifications and experience
Bachelor’s degree in Mechanical Engineering, Automotive Engineering, Mechatronics or a closely related discipline; a relevant postgraduate qualification is an advantage.
Typically 8 or more years of relevant design engineering experience, including demonstrated responsibility for hydraulic power packs, mobile equipment or vehicle system integration.
Experience designing or integrating hydraulic systems and working with engine, cooling, transmission, brake and axle interfaces in a chassis or comparable equipment platform.
Working knowledge of design calculations, component sizing, hydraulic schematics, engineering drawings, bills of materials, prototype validation and manufacturing support.
Experience reviewing engineering work and providing technical guidance to engineers or design teams.