Aluminium Profile & Systems Design Engineer

About the role MAO is building extrusion capacity that does not yet exist in the Middle East, including four 50 MN 12-inch presses for large industrial sections. This role turns customer needs into profiles and systems that can be extruded, fabricated and certified here, and sold as Made in Saudi. You will own the design of a profile from first sketch to approved die drawing and production sample. You will also design complete systems, where several profiles, connectors, fasteners and accessories work together as one product. Target applications include structural and industrial sections, offshore helidecks, truck and trailer sidewalls, large cable trays, solar mounting, marine sections, tent and shelter frames, oil and gas sections, heat sinks, and architectural fins and mullions. Key responsibilities Profile design Design new extrusion profiles from customer drawings, samples or functional briefs, in 6xxx alloys (6060, 6063, 6005A, 6061, 6082) and others where needed. Optimise sections for extrudability: wall thickness ratios, tongue ratios, hollow and semi-hollow features, circumscribing circle diameter and press size. Minimise weight per metre while meeting strength, stiffness and functional targets. Specify tolerances to EN 755-9 / EN 12020 or ASTM B221 / ANSI H35.2, and surface requirements for anodising or powder coating. Produce release drawings and work with the die shop and die makers on die design, die trials and corrections. System design Design complete systems: profiles, joints, connectors, fixings, gaskets and accessories that assemble into a working product. Develop industrial systems such as structural frames, platforms, cable management, solar structures and modular framing. Design for fabrication and assembly: machining, CNC, bending, welding and bolted connections. Build system catalogues, technical data sheets and installation guidance. Structural engineering Calculate section properties (area, Ixx, Iyy, Zx, Zy, J) and check members to Eurocode 9 (EN 1999), the Aluminum Design Manual or equivalent. Run FEA on critical profiles and connections, including deflection, buckling, fatigue and thermal effects. Account for heat-affected zone strength loss in welded designs. Support third-party certification and testing for structural and offshore products. Customer and commercial support Work with sales on technical enquiries, feasibility and cost-driven redesign (value engineering). Meet customers to understand application, loads and installation conditions. Advise on alloy, temper and finish for each application. Engineering management Maintain the profile library, drawing numbers, revisions and die register. Set up design standards and checklists for the engineering team. Train junior designers and draughtsmen as the team grows. Requirements Education Bachelor's degree in Mechanical, Structural, Civil or Materials Engineering. Experience 8+ years designing aluminium extrusion profiles, with at least 5 years at an extruder, system house or die maker. Proven record of profiles taken from concept to production, with a portfolio of released designs. Experience designing complete aluminium systems, not only individual sections. Hands-on work with die designers and press teams on die trials and corrections. Technical knowledge Extrusion process: billet, die types (solid, porthole, bridge), press capacity, extrusion ratio, quench and ageing. Aluminium alloys and tempers, mechanical properties and their effect on design. Profile tolerances and standards: EN 755, EN 12020, ASTM B221, ANSI H35.2. Structural design to Eurocode 9 or the Aluminum Design Manual. Joining methods: welding (MIG/TIG, friction stir), bolting, clinching, snap-fit and screw ports. Surface treatment: anodising, powder coating and their design implications. Software 2D and 3D CAD: AutoCAD plus SolidWorks, Inventor or CATIA. FEA: ANSYS, Abaqus, SolidWorks Simulation or similar. Section property and structural tools (e.g. RFEM, SAP2000, STAAD, or in-house tools). Language Fluent English, written and spoken. Arabic is an advantage. Preferred qualifications Experience with industrial and structural profiles — large sections from 10–12 inch presses or above, wide flat panels, interlocking deck planks, heavy hollows. Design work in one or more of: offshore and helidecks, transport (trailers, rail, truck bodies), marine (5083 / 6061), solar mounting, scaffolding and formwork, temporary structures, defence. Designs approved by classification or certification bodies (DNV, ABS, Lloyd's, CAP 437 for helidecks, TÜV). Friction stir welding of wide panels from narrow extrusions. Master's degree in structural or mechanical engineering, or a chartered/PE status. GCC or Saudi experience, and familiarity with Aramco or SASO requirements. Show more Show less