Mechanical Engineer- Thermal Systems & CFD in Sunbury-on-Thames

We are seeking a Mechanical Engineer with a background in fluid flow, thermal design, and mechanical product development—such as fans, blowers, heaters, and vapour cycle thermal systems—to join our Technology & Product Development team. You will contribute to the design, analysis, verification, and sustainment of advanced thermal management products for aerospace and defense applications, including vapour cycle cooling systems, HVDC fan heaters, blowers, and other custom (build-to-specification) electro-mechanical systems engineered for demanding environments.

This is an exciting opportunity to influence next-generation thermal management solutions within a multidisciplinary new product development team, combining CFD, thermal/structural FEA, rigorous engineering governance, and hands-on prototype and shop-floor engagement.

• Provide engineering input for bids and proposals, including feasibility assessments, preliminary sizing, thermal performance estimates, and risk identification.
• Support the interpretation of technical requirements and collaborate with cross-functional teams to contribute to an overall coherent design.
• Review and approve CAD models, drawings, and mechanical layouts to ensure accuracy, manufacturability, and compliance with internal standards and customer requirements.
• Perform CFD analyses (airflow, pressure drop, thermal distribution, multiphase where applicable) to support design optimization.
• Support the design and development of vapor cycle systems, including component selection, thermodynamic modelling, and integration activities.
• Contribute to the development of new and existing products such as HV DC fan heaters, blowers, fans, and other forced-air thermal management components.
• Collaborate with cross-functional teams—electrical engineering, systems engineering, manufacturing, and test—to ensure robust product development.
• Ensure compliance with aerospace and defense standards, including performance, reliability, and safety requirements.
• Produce engineering documentation including design reports, analysis summaries, qualification test plans, and verification evidence.
• Assist in the generation of design documentation, compile test results and technical reports and other associated project deliverables.
• Hands on person to help shopfloor to test and build products supporting Manufacturing Engineering.

• Bachelor’s degree in mechanical or aerospace engineering, or a related discipline.
• Strong grasp of mechanical principles, fluid dynamics, and heat transfer, applied to mechanical and electro-mechanical systems.
• Proven experience in thermal design and air-moving products (e.g., fans, blowers, heaters) and/or cooling systems.
• Knowledge of vapour cycle refrigeration (system components, control strategies, refrigerants, performance maps).
• Competent with CAD (e.g., SolidWorks, Inventor, or similar) and interpretation/approval of engineering drawings with GD&T.
• Experience producing engineering documentation (design reports, analysis evidence, test plans, verification records) to a high standard.
• Effective, structured problem-solving and root-cause capability; familiarity with DFMEA and risk management.
• Demonstrated ability to interpret technical requirements and create coherent machine-level design solutions.

• Experience in DFMEA, failure analysis, technical risk management, and structured problem-solving methodologies.
• Hands-on mindset with the ability to work directly with prototype hardware and manufacturing teams, willingness to support shop-floor builds and testing.
• Exposure to thermal and mechanical FEA (CFD, thermal, structural).
• Experience with systems modelling tools (e.g., Siemens Amesim, AVL KULI) is advantageous.
• Proficiency with MS Office for analysis, reporting, and presentations.
• Experience within aerospace, defense, automotive electrification, or high-reliability industries.
• Background in scripting languages and AI.

• Strong communication and teamwork skills; ability to collaborate across disciplines and with suppliers/manufacturing.
• Ability to work within company processes, configuration control, and quality systems.
• Strong organisational skills and the ability to manage multiple priorities in parallel.
• Positive, proactive attitude and willingness to operate as a part of a global team.