Thermal System Engineer (ICE & Electrified Powertrain) in London

Location: Gaydon, UK

Type of employment: Permanent

Role Overview

We are seeking a highly motivated Cooling System Engineer with 5-6 years of automotive experience to support the development and delivery of advanced thermal management systems for both internal combustion engine (ICE) and electrified powertrain applications (MHEV/PHEV). This role involves full lifecycle ownership from concept definition through to design, validation, and release, ensuring robust delivery aligned with premium vehicle performance, durability, and quality targets.

Key Responsibilities

• Lead the design and development of vehicle thermal systems, including radiators, condensers, charge air cooling, battery cooling circuits, and thermal integration of powertrain systems.
• Define and cascade system requirements, working cross-functionally with powertrain, vehicle attributes, CAE, and packaging teams.
• Deliver complete thermal system architectures for ICE and electrified platforms (PHEV/MHEV), including integration with HVAC, battery, and e-drive systems.
• Develop and maintain Design Verification Plans (DVP) and execute validation activities including test planning, data analysis, and reporting.
• Create, maintain and manage DFMEA documentation, including P-diagrams and boundary diagrams, ensuring design robustness and failure mitigation strategies.
• Work closely with suppliers to support component design, sourcing, and manufacturing feasibility, ensuring cost and quality targets are achieved.
• Support prototype builds, validation events, and issue resolution, including root cause analysis and corrective actions.
• Ensure all components are released in line with programme gateways and client-specific release processes (AML standards).
• Provide technical support for in-service and warranty concerns, ensuring continuous improvement of system reliability.

Skills & Technical Competencies

• Strong understanding of vehicle thermal management and heat transfer principles, including ICE and electrified systems.
• Proficiency in Siemens NX (Unigraphics) for 3D modelling, packaging, and design release activities.
• Experience in DFMEA, DVP&R processes within automotive product development.
• Familiarity with PLM tools (Teamcenter) and engineering change/release processes (ECR/ECO).
• Knowledge of cooling system components such as radiators, pumps, valves, heat exchangers, and refrigerant circuits.
• Experience with hybrid and electric vehicle architectures, including battery thermal management and HV systems.
• Strong analytical and problem-solving skills, with the ability to interpret test data and simulation outputs.

Experience Required

• Minimum 5-6 years experience in automotive thermal system or thermal systems engineering.
• Proven experience delivering cooling systems from concept to production release.
• Experience working with OEM clients, ideally within a premium automotive environment such as Aston Martin or equivalent.
• Hands-on experience with prototype builds, testing, and validation programmes.

Core Behaviours

• Strong collaboration skills, working effectively in cross-functional engineering teams.
• Ability to manage multiple deliverables within programme timelines.
• Proactive mindset with strong ownership of deliverables and technical decisions.
• Excellent communication skills, both written and verbal.