Thermal Engineer

At ZeroAvia, we’re clean sky thinkers. For the world to achieve truly clean, guilt-free flight, we need a scalable solution; hydrogen-electric powertrains. As a leader in zero-emission aviation and a UK Jet Zero Council member, we’re designing and commercialising hydrogen-powered solutions that will positively impact the future of aviation, global connectivity, and the world.

Engineering designs our next-generation hydrogen electric engines. Working across Hydrogen, Propulsion and Integration divisions, they solve technical problems and help decarbonize aviation by finding solutions for electric propulsion, hydrogen storage, fuel cell technology, power distribution, thermal management and more.

Working closely with other engineering functions, assume responsibility for all aspects of thermal management of power and propulsion systems. Demonstrate recent practical experience and comprehensive knowledge of various thermodynamic technologies to help meet current and future system requirements. Be prepared to act as a subject matter expert and lead on thermal topics.

Dynamic approach to complex problem solving including utilising empirical methods, basic calculations from first principles and 1D & 3D simulation tools. Use CAD to create designs and drawings of related system components and assemblies, and maintain design data in PLM system in accordance with company and industry standards.

Self-starter, diligent, results focused and flexible. Aerospace experience, knowledge of CAA, EASA, FAA certification processes and objectives a plus.

Requirements

Main responsibilities

• Development of thermal management components and systems for fuel cell electric powertrains.
• Innovative thermal concept generation, prototype design and development.
• Detailed design, analysis, testing and verification in line with aerospace regulations.
• Definition of thermal system requirements and equipment specifications interfacing with
• Systems Engineering teams to deliver thermally optimised solutions.
• Liaise with internal and external stakeholders to ensure accurate and efficient implementation of thermal solutions.
• Development of CAD geometries of thermal system components and designs including preparation of simple manufacturing part and assembly drawings.
• Host, participate, present as appropriate in internal and external design and project reviews
• Perform numerical simulation and optimisation of components and systems using a range of tools including hand calculations, 1D thermofluid modelling and CFD analysis.
• Development and improvement of internal analysis and data processing tools from first principles.
• Plan and conduct ground test campaigns to characterise equipment and verify system level requirements.
• Provide subject matter expertise relating to integration of thermal system components.
• When necessary, be responsible for / assist with fault finding and issue resolution.
• Support reporting of project timing and cost management for area of design responsibility

Experience and Qualifications

• Education: Bachelor's degree in an appropriate discipline and commensurate depth of technical experience, or an equivalent combination of education and experience
• 3-5 years first hand knowledge of implementing innovative design solutions relevant to thermal systems.
• Conversant with associated components such as heat exchangers, pumps, valves and sensors, etc.
• Hands-on experience of testing and validation in physical and/or virtual domains
• Proficient at hand calculations and coding using Matlab and/or Python
• User of 1D thermo-fluid analysis (e.g. Matlab Simscape)
• Experience of commercial CFD codes (e.g. Ansys Fluent, Siemens Star CCM+)
• Competent user of CAD and PLM tools (e.g. Simens NX) including preparation of engineering drawings, P&IDs, surface modelling a plus
• Knowledge of materials, finishes and other processes including additive manufacturing
• Working knowledge of phase change, high and low temperature thermodynamics a plus
• Prior knowledge of H2 fuel cell and/or electric powertrain cooling systems a plus
• Experience of high voltage enclosures, power electronics and associated thermal management practices a plus
• Have the ability to assimilate technology and technical details quickly and communicate the requirements clearly to ZeroAvia colleagues and stakeholders
• Excellent interpersonal skills and level of spoken and written English, additional languages a plus
• Ability to work on own initiative as well as part of a growing multinational team

Benefits

Stock Options

Relocation support

️ Holiday: 25 Days + Public Holidays

Kemble Location: Free Lunch

EV Club and Kemble Free EV Charging

️ Flying Club: 5 free hours of flying lessons + Discount on Pilots License (PPL)

‍⚕️ Private Healthcare: Plus Dental, Optical, Mental health support

Salary sacrifice schemes: EV Club, Curry's Tech, Cycle to Work and Ikea Furniture

Weekly Spot Bonuses

‍⚖️ Income protection and Legal support