Senior Aerothermal Engineer

ZeroAvia is seeking a Senior Aerothermal Engineer to lead the aerothermal design and development of air delivery systems for its hydrogen fuel cell powertrains. The role is ideal for an experienced aerospace engineer with deep expertise in air system architecture, turbomachinery, and thermo‑fluid analysis, who can take full technical ownership from concept generation through certification‑ready design, testing, and supplier integration.

Acting as a subject matter expert, the successful candidate will work across multidisciplinary teams and the supply chain to develop, analyse, and validate fuel cell cathode and air delivery systems using first‑principles analysis, simulation, and empirical testing, supporting the certification and deployment of ZeroAvia’s current and future zero‑emission propulsion systems. The Senior Aerothermal Engineer will assume responsibility for all aspects of aerothermal design of air delivery systems for hydrogen fuel cell power generation systems.

Working with internal stakeholders and the supply chain you will develop and demonstrate air delivery equipment and architectures to support certification of current and future hydrogen fuel cell power generation systems. Acting as the subject matter expert, you will lead on air delivery system topics technical discussions. You’ll need a dynamic approach to complex problem solving including utilising empirical methods, basic calculations from first principles and 1D & 3D simulation tools. You’ll use CAD to create designs and drawings of related system components and assemblies and maintain design data in PLM system in accordance with company aeronautical standards.

To succeed in this role, you’ll be a self‑starter, diligent, results focused and flexible. Aerospace experience, knowledge of CAA, EASA, FAA certification processes and objectives are a huge advantage.

• Own all aspects of fuel cell cathode system development; including system architecture, requirements capture, equipment design development and testing.
• Lead aerothermal concept generation through to development of system architecture, requirements and design substantiation documents.
• Analyse air delivery systems and components to define lower level functional and performance requirements.
• Proactively lead internal stakeholders and supply chain on implementation of air delivery system equipment such as electric compressors, filters, valves, heat exchangers, fluid conveyance and instrumentation.
• Develop strategies and capabilities for component level engineering evaluation testing including design, installation and commissioning of equipment test rigs.
• Host, participate, present as appropriate in internal and external design and project reviews.

• Education: Bachelor's degree in an appropriate discipline and commensurate depth of technical experience, or an equivalent combination of education and experience.
• First‑hand knowledge of implementing compressed air systems and equipment with direct experience in hydrogen fuel cell system an advantage.
• Experience in implementation of high‑speed turbomachinery (compressors, turbines) and associated system architectures.
• Conversant with associated hardware such as compressors, filters, valves, humidifiers and sensors.
• Experience in developing air delivery equipment test rigs including instrumentation and data acquisition systems, knowledge of programming environments (e.g. "LabVIEW") a plus.
• Experience of high voltage direct current (HVDC) systems and power electronics a plus.
• User of MATLAB Simulink/Simscape or similar 1D thermo‑fluid software.
• Experience of commercial CFD codes (e.g. "Ansys Fluent/CFX").
• Working knowledge of CAD and PLM tools (e.g. Siemens NX, Teamcentre).
• Use of requirements management tools (e.g. Polarion).
• Commensurate depth of related aerospace industry experience.
• Excellent interpersonal skills and level of spoken and written English.
• Ability to work on own initiative as well as part of an Integrated Project Team.

• Private health and dental care – get access to services and support when you need them. Add your family members too.
• Mental health support – enjoy a culture where positive mental health is front of mind with our trained Mental Health First Aiders, Employee Assistance Programmes and wellbeing support.
• Free lunch and healthy snacks – keeping you fuelled up so you can help us deliver the technology of the future.
• Sports, games and culture clubs – connect and keep fit with other ZeroAvians by joining one of our clubs – such as, running, cycling, padel, trivia, theatre and gardening.
• Stock options – so you can share in our success.
• 25 days holiday, plus public holidays and additional days awarded for long service – to help you manage your work‑life balance.
• Free EV Charging and membership in our EV Club.
• Salary Sacrifice Schemes for EV Club, Curry's Tech and Cycle to Work.
• Weekly Spot Bonuses to reward excellence.
• Income Protection and Legal Support for peace of mind.
• Relocation Support to make your move seamless.

As an emergent company shaping the aviation industry, we know that diversity fuels success and unlocks potential. We embrace being an equal‑opportunity employer and actively seek individuals from diverse backgrounds. We value the multitude of skills, perspectives, and mindsets everyone can bring to the table. These experiences ignite creativity, originality, and growth. We proudly reject discrimination in all forms, including that based on race, religion, color, national origin, sex, gender expression, sexual orientation, age, marital status, veteran status, or disability status.