Fuel System Design Engineer (High-Performance Automotive)

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