Senior Thermal Engineer

Company Overview

Aed Energy Ltd is a pioneering energy storage technology company at the forefront of developing long-duration energy storage systems with dual heat and power delivery. Our systems convert electricity into high-temperature heat and regenerate it using thermophotovoltaics. We are looking for a capable and hands-on Senior Thermal Engineer to join our growing team and support the design and testing of our next-generation MWh-scale storage systems.

Job Overview

As Senior Thermal Engineer at Aed Energy, you will take ownership of high-temperature system modelling, mechanical analysis, and validation. You will be responsible for detailed CFD and thermal simulations, component-level design, material selection, and lab-based testing of assemblies operating up to 1000°C. You will collaborate across mechanical, electrical, and systems engineering to deliver robust, manufacturable, and scalable thermal designs. This role is ideal for an engineer with strong simulation and experimental skills, who is excited to build real hardware and contribute directly to product performance in a fast-paced startup environment.

Key Responsibilities

• Build and troubleshoot large-scale CFD models covering multi-scale thermal and fluid dynamics phenomena.
• Conduct conjugate heat transfer simulations, modelling interactions between fluids, solids, and insulation layers.
• Perform mechanical stress and thermal expansion analysis of high-temperature components and assemblies.
• Analyse and optimise system heat balances and process flow diagrams (PFDs).
• Design and evaluate resistive heaters, storage modules, insulation systems, heat exchangers, and support structures.
• Lead or support material selection for thermal, structural, and insulation performance at elevated temperatures.
• Create and manage mechanical designs using CAD tools (e.g. SolidWorks, Fusion 360) and ensure manufacturability.
• Work with complex and non-ideal CAD geometries to ensure simulation and fabrication readiness.
• Set up and operate lab-based thermal test rigs, capturing temperature, flow, pressure, and mechanical performance data.
• Generate and interpret validation datasets to calibrate simulation models and inform design decisions.
• Document assumptions, results, and recommendations clearly for internal and external stakeholders.

Qualifications

• Bachelor's or higher degree in Mechanical Engineering, Thermal Sciences, or a related discipline.
• Minimum 5 years of experience in thermal and mechanical engineering, with demonstrable CFD and FEA modelling capability.
• Strong understanding of heat transfer (conduction, convection, radiation), structural mechanics, and thermal-fluid systems.
• Proficiency in thermal and mechanical simulation tools such as ANSYS, COMSOL, or OpenFOAM.
• Hands-on experience with CAD software (e.g. SolidWorks, AutoCAD, Fusion 360), including modelling for manufacture.
• Experience with material selection and trade-offs at high temperature, including metals, ceramics, and insulation.
• Experience with lab instrumentation (thermocouples, IR cameras, load sensors, DAQs) and mechanical testing setups.
• Working knowledge of Python, MATLAB, or similar tools for data analysis and automation.
• Strong analytical, problem-solving, and cross-functional collaboration skills.

Preferred Qualifications

• Experience with thermal radiation modelling and long-term material durability at high temperature.
• Background in heat exchanger or boiler system design.
• Familiarity with air-handling systems, ducting, fans, or convective system optimisation.
• Experience designing systems for thermal cycling, fatigue, and harsh operating environments.
• Prior experience in industrial heat, energy storage, or advanced manufacturing settings.

Benefits

• The opportunity to work on transformative, climate-positive energy technology that not only drives innovation but also significantly contributes to a sustainable future, impacting communities and environments globally.
• A hands-on, collaborative role within a dynamic and mission-driven startup team, where every member's input is valued, fostering a culture of creativity and collective problem-solving.
• A competitive salary, complemented by attractive equity options that allow you to share in the success of the company and rewards you for your hard work and commitment.
• Access to our state-of-the-art in-house thermal lab and advanced prototyping facilities, providing you with the tools necessary to turn innovative ideas into reality and to engage in hands-on experimentation and development.
• Clear paths for both technical development and leadership opportunities as the team expands, ensuring you have the support and resources needed to grow your career in alignment with our strategic objectives and your personal aspirations.

Mid-Senior level

Full-time

Industries

IT Services and IT Consulting