Principal Engineer - Product Safety

Job title: Product Safety Engineer (UAV, Drone, Aviation, Aircraft, Avionics)
Location: Maidenhead, Berkshire
Salary: Negotiable

Malloy Aeronautics Limited specializes in the development of heavy lift unmanned air vehicles (UAVs) for both civilian and military uses. Located in Berkshire, our operations are notable for their focus on in‑house design and manufacturing. This vertical integration means we control the production of most aircraft components on‑site, enhancing our ability to innovate and maintain high standards across all stages of development.

As a Safety Engineer, you will report to the Chief Engineer. This exciting role places the right candidate at the forefront of unmanned air systems development in the UK. You will oversee the development and implementation of safety processes for UAS systems, drive the integration of safety requirements into engineering designs, and ensure compliance with regulatory standards and industry best practices.

Your expertise in safety engineering and risk management will be applied to assess hazards, develop safety cases, and maintain product integrity throughout the lifecycle. You will also collaborate with cross‑functional teams to promote a strong safety culture, providing guidance, training, and continuous improvement initiatives across the organization.

• Evaluation of aircraft and system / sub‑system design safety in support of platform safety certification throughout the engineering life cycle.
• Generating, updating and reviewing aircraft, system and sub‑system safety engineering tasks such as decomposition of safety requirements at all relevant product levels (weapon platform, system, sub‑system, equipment).
• Zonal Hazard Analysis Reports (ZHAs), preliminary hazard list (PHL) and preliminary hazard analysis (PHA).
• System / sub‑system hazard analysis.
• Validation of supplier safety analysis / documentation.
• System / sub‑system safety assessment reports, including safety analysis (fault tree analysis, etc.).
• Ensuring that certification evidence supports achievement of an acceptable level of product design safety with respect to design airworthiness requirements and identified hazards.
• Assess customer deviations from the design for adverse impact on product integrity and identify recovery routes where necessary.
• Support project teams and support and service engineering organisations with the generation of risk assessments, ensuring suitable justification exists for action and the adequacy of the proposed remedial / recovery action in mitigating product safety risk / safety performance degradation.
• Undertake the communication and management of residual risk through the appropriate process.
• Manage and report any outstanding product integrity actions/issues through to closure.

• Establishing and delivering the engineering activities using systems integration and systems engineering techniques.
• Sustaining the initial integrity of Malloy products through production challenge and review of design, certification and assurance evidence (including product data requirements) in line with market legislation and regulatory obligations.
• Sustain the Malloy Engineering regarding product integrity through the development / improvement of existing processes and operations, challenging the norm, promoting efficiency and competitiveness whilst ensuring continuous delivery.
• Validate and challenge the initial evidence through professional judgement and constructive feedback, performance of audit and assurance activities, including involvement in design and phase review assessments (as appropriate).
• Recovery of the integrity of Malloy products through investigation, root cause analysis, technical instruction (using technical writing skills) and advising of potential design change.
• Exploitation of learning across Air and other BAE Systems units, customers and suppliers using appropriate alerting, lessons learnt and promotional processes.

• Qualified to degree level or equivalent in a relevant STEM discipline.
• Minimum 3 to 5 years of experience in a similar product…