Overview
Expleo is a trusted partner for end-to-end, integrated engineering, quality services and management consulting for digital transformation. We help businesses harness unrelenting technological change to successfully deliver innovations that will help them gain a competitive advantage and improve the everyday lives of people around the globe.
An exciting opportunity has arisen for a Fuel System Design Engineer to join a high-performance automotive engineering environment, supporting the design, development, integration, and validation of advanced fuel system architectures for next-generation vehicle programmes.
This role will focus on the end-to-end development of fuel system components and assemblies, from concept definition through to prototype, validation, and production release. The successful candidate will work across multidisciplinary engineering teams to deliver high-quality, manufacturable fuel system solutions that meet demanding performance, packaging, durability, regulatory, and timing targets. The position requires strong mechanical design capability, hands-on engineering understanding, and experience working with fluid systems in high-performance automotive or related engineering sectors.
Responsibilities
Fuel System Design & Development
- Design and develop complete fuel system architectures and associated components for high-performance vehicle applications.
- Lead or support development of:
- Fuel tank assemblies
- Fuel filler systems
- Fuel pumps and filtration systems
- Fuel lines, manifolds, and sensors
- EVAP systems and charcoal canister integration
- Fuel retention and mounting systems
- Fuel metering and control components
- Develop detailed 3D CAD models, assemblies, and engineering drawings for fuel system components and installations.
- Perform vehicle integration and packaging studies to ensure compatibility with overall vehicle architecture and packaging constraints.
- Support concept generation and evaluation for new fuel system technologies and layouts.
Engineering Analysis & Simulation
- Use engineering calculations, modelling tools, and simulation methods to size and optimise fuel systems and fluid control components.
- Conduct fluid system analysis using:
- CFD tools
- FEA methods
- Thermal and flow simulations
- Evaluate system performance, durability, manufacturability, and reliability.
- Support tolerance analysis, stack-up assessments, and DFMEA activities.
Prototype, Validation & Testing
- Develop component and system-level validation plans and support execution of testing activities.
- Support in-house prototype builds and vehicle integration activities.
- Collaborate with test and validation teams on:
- Rig testing
- Pressure and leak testing
- Environmental and durability testing
- System verification and issue resolution
- Support development of bespoke test equipment and validation methodologies where required.
Engineering Release & Documentation
- Produce and maintain engineering documentation including:
- CAD data (2D & 3D)
- BOM structures
- Engineering release documentation
- Technical specifications
- Change requests and issue tracking
- Support engineering release processes ensuring designs meet internal standards, gateway deliverables, and regulatory requirements.
- Ensure CAD and engineering data are fully production-ready and compliant with DFM principles.
- Support BOM management, engineering change processes, and configuration tracking throughout programme lifecycle.
Cross-Functional Collaboration
- Work closely with:
- Vehicle integration teams
- Manufacturing and prototype build teams
- Suppliers and external partners
- Test and validation engineers
- Purchasing and programme management teams
- Participate in design reviews and technical discussions to ensure robust and optimised engineering solutions.
- Support supplier management activities, including technical reviews and component development coordination.
Qualifications
- Bachelor’s or Master’s degree in Mechanical Engineering, Automotive Engineering, Mechatronics, or a related engineering discipline.
- Strong understanding of mechanical systems and fluid system engineering principles.
Essential skills
Fuel System Engineering
- Proven experience designing and developing automotive or high-performance fuel systems and associated components.
- Strong understanding of:
- Fluid systems
- Fuel routing and packaging
- EVAP systems
- Pumps, valves, and filtration systems
- Fuel storage and delivery systems
CAD & Engineering Design
- Proficiency in CAD software such as:
- CATIA V5
- or equivalent 3D CAD platforms
- Experience producing:
- Detailed component and assembly models
- Manufacturing drawings
- GD&T-compliant engineering documentation
Simulation & Analysis
- Experience using engineering analysis and modelling tools such as:
- ANSYS
- Mathcad
- CFD / FEA software
- Ability to perform engineering calculations and support system optimisation through simulation-driven design.
Engineering Processes
- Strong understanding of:
- DFM (Design for Manufacture)
- DFMEA
- Engineering release processes
- BOM management
- Product development lifecycle activities
- Familiarity with automotive standards and engineering documentation practices.
Communication & Delivery
- Strong communication and collaboration skills.
- Ability to work effectively both independently and within cross-functional engineering teams.
- Proactive approach to problem solving and continuous improvement.
Experience
- Proven experience in fuel system design within:
- Automotive
- Motorsport
- Aerospace
- Commercial vehicle
- or other high-performance engineering sectors.
- Experience developing mechanical and fluid systems from concept through to production release.
- Experience supporting prototype builds, system integration, and validation activities.
- Hands-on experience working with manufacturing, suppliers, and test teams.
- Experience managing engineering changes and technical issue resolution throughout programme delivery.
- Exposure to high-performance or low-volume vehicle development environments is advantageous.
Benefits
- Collaborative working environment – we stand shoulder to shoulder with our clients and our peers through good times and challenges
- We empower all passionate technology loving professionals by allowing them to expand their skills and take part in inspiring projects
- Expleo Academy - enables you to acquire and develop the right skills by delivering a suite of accredited training courses
- Competitive company benefits
- Always working as one team, our people are not afraid to think big and challenge the status quo
- As a Disability Confident Committed Employer we have committed to:
- Ensure our recruitment process is inclusive and accessible
- Communicating and promoting vacancies
- Offering an interview to disabled people who meet the minimum criteria for the job
- Anticipating and providing reasonable adjustments as required
- Supporting any existing employee who acquires a disability or long term health condition, enabling them to stay in work at least one activity that will make a difference for disabled people
“We are an equal opportunities employer and welcome applications from all suitably qualified persons regardless of their race, sex, disability, religion/belief, sexual orientation or age”.
We treat everyone fairly and equitably across the organisation, including providing any additional support and adjustments needed for everyone to thrive
