R and D Technician – Mechanical

The R&D Technician – Mechanical builds, assembles, tests and maintains the mechanical systems of R&D prototypes. These include UAV airframes, propulsion and fuel systems, mechanisms, UAV launch systems and other ground equipment. The technician works hands‑on with the mechanical engineers, from the first prototype to flight test.

Key Responsibilities

PROTOTYPE BUILD AND ASSEMBLY

• Assemble airframes and structures from drawings and BOMs: fuselages, wings, tails, landing gear, payload bays and hatches.
• Bond parts with structural adhesives: prepare surfaces, mix and apply adhesive, control bond lines, clamp and cure as specified. Record adhesive batch numbers and cure data.
• Do composite work on carbon and glass fiber parts: wet lay-up, vacuum bagging, trimming, sanding, filling, insert potting and repairs.
• Install fasteners and hardware: torque to specification, apply thread locker and torque marks, install inserts, rivets and thread repair inserts.
• Install and adjust mechanisms: control surfaces and linkages, servos, hinges, folding and release mechanisms, doors and latches.
• Install propulsion parts: electric motors, engines, propellers, mounts, fuel tanks, fuel lines and cooling parts.
• Assemble and align ground equipment: launcher rails, carriages, brakes and frames, transport cases and ground support equipment.
• Make simple parts, jigs and fixtures: drill, tap, cut, file, basic lathe and milling work, and 3D printing.

TEST, MEASUREMENT AND FIELD SUPPORT

• Measure and record weight and center of gravity (CG). Add ballast to get the target CG.
• Rig control surfaces: set neutral positions, deflections and directions. Check alignment and symmetry of wings and tails.
• Do leak tests on fuel systems. Balance propellers. Inspect engine installations before ground runs.
• Prepare and support structural, functional and vibration tests: set up rigs, apply loads, install instrumentation and record results.
• Support ground runs and flight tests at test sites: assembly, pre-flight mechanical checks, launch and recovery preparation, post-flight inspection and damage assessment.
• Measure parts and assemblies with calipers, micrometers, height gauges, inclinometers and torque tools. Report non-conformances.

MAINTENANCE AND CONFIGURATION CONTROL

• Keep R&D prototypes and ground equipment ready for test. Do scheduled inspections, lubrication, repairs and modifications.
• Keep a record for each prototype: build state, modifications, replaced parts, weight and CG, flight hours and defects.
• Keep the stock of fasteners, adhesives, composite materials, consumables and spare parts at the correct level. Monitor the shelf life of adhesives and resins. Tell procurement before stock runs out.

BRIDGE TO PRODUCTION

• Build the first (pilot) production units together with the assembly team. Find and report design features that make the product hard to build, align or inspect.
• Make assembly and bonding jigs, drilling templates and inspection gauges together with the engineers.
• Write and validate work instructions with photos for assembly, bonding, rigging and set-up. Include torque values, cure times and inspection points.
• Train production and assembly staff in surface preparation, adhesive handling, bonding, fastening and torque, composite repair, rigging and weight and balance. Check their work and sign them off when they are competent.
• Support production with technical problems and non-conformance investigations. Send the lessons learned back to R&D.

WORKSHOP, SAFETY AND QUALITY

• Keep the mechanical workshop, tools and machines clean, safe and organized (5S).
• Obey the safety rules for machines, resins, adhesives, solvents, fuels, composite dust and propellers. Use the correct PPE.
• Make sure that torque tools and measuring equipment are calibrated and in good condition.
• Follow company quality procedures. Record material batches and inspection results.

Qualifications And Experience

• Diploma, associate degree or technical certificate in mechanical engineering, aeronautical engineering, mechatronics or aircraft maintenance.
• Minimum 3 years of hands‑on experience in mechanical assembly, composite work or aircraft maintenance. Experience in UAV, aerospace, defense, motorsport or marine composites is preferred.
• An aircraft maintenance licence or military aircraft maintenance experience is an advantage.
• Experience in training other people or writing work instructions is an advantage.

Technical Skills

• Read engineering drawings, including tolerances and basic GD&T. Work from BOMs and 3D models.
• Structural bonding: surface preparation, mixing, application and cure control.
• Composite lay-up, vacuum bagging, trimming and repair.
• Correct use of hand and power tools, torque tools and precision measuring tools.
• Basic machining: drill, tap and cut. Safe use of workshop machines.
• Good computer skills: CAD viewers, spreadsheets and MS Office.
• Prepreg handling and oven or autoclave cure.
• Small piston engines or small gas turbines, and their fuel systems.
• Propeller balancing, and motor or engine test stands.
• 3D printing (FDM, SLA) and laser-cut parts.
• Basic CAD (for example SolidWorks) to design simple jigs and fixtures.
• Launch and recovery systems: catapults, launcher rails, parachutes.
• Basic electrical knowledge to work safely near avionics and batteries.

PERSONAL ATTRIBUTES

• Careful and precise. Checks the work before it goes to the next step.
• Patient teacher. Explains a task step by step and makes sure the other person understands it.
• Solves problems logically. Records what was found and what was done.
• Works well in a small team where priorities change quickly. Stays calm during test campaigns.
• Good spoken and written English.

WORKING CONDITIONS

• Based in the R&D workshop and laboratories in Masdar City, Abu Dhabi.
• Regular work at outdoor test sites in the UAE, sometimes in high heat.
• Works with resins, adhesives, solvents, fuels, composite dust and workshop machines. Obeys company safety rules and uses the correct PPE.
• Lifts and moves equipment up to 25 kg. Uses a team lift or lifting aids for heavier items.
• Must pass the company security screening. A valid UAE driving licence is an advantage.

How Success Is Measured

• Prototypes are ready for test on the planned date.
• Builds pass inspection without rework. Weight and CG are within the target.
• Prototype records (build state, modifications, defects) are complete and correct.
• Each product that moves to production has released work instructions, jigs and inspection points.
• Assembly staff are trained and signed off, and production builds meet quality targets after the handover.

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