Senior Thermal Engineer

We are seeking a highly skilled Thermal Management Engineer to take full ownership of thermal design, analysis, and system performance across power and propulsion applications, working closely with cross‑functional engineering teams. This role is suited for a confident, independent engineer with deep expertise in thermodynamic technologies, strong capability in empirical methods, first‑principles calculations, and 1D/3D simulation tools, along with the ability to lead technical discussions and act as a subject matter expert on thermal topics. The position also requires proficiency in CAD for designing and documenting thermal system components and maintaining design data within a PLM environment; aerospace experience and familiarity with CAA, EASA, and FAA certification processes are strong advantages.

ZeroAvia is at the forefront of building a new clean‑aviation ecosystem, and the successful candidate will be joining a world‑class team that is passionate about developing solutions that are not only zero‑emission but also commercially competitive and technically groundbreaking.

Main Responsibilities:

• All aspects of thermal management system development from design to manufacture; including requirements capture, system and component analysis, requirements specification, prototyping and testing.
• Develop thermal management solutions applied to a fuel cell system including full balance of plants and interface with aircraft and other powerplant systems.
• Liaise closely with internal and external stakeholders to ensure accurate and efficient implementation of thermal solutions and requirements.
• Lead thermal management system concept generation through to development of system architecture, requirements and design substantiation documents.
• Analyse thermal management systems and components and define lower level functional and performance requirements.
• Work with internal teams and the supply chain on delivery of thermal management system equipment such as heat exchangers, pumps, valves, fluid conveyance and instrumentation.
• Determination of strategies for component level engineering evaluation testing including design, installation and commissioning of test rigs.
• Host, participate, present as appropriate in internal and external design and project reviews.

Experience and Qualifications:

• Education: Bachelor's degree in an appropriate engineering discipline.
• First hand knowledge of implementing innovative thermal management solutions.
• Prior knowledge of H2 fuel cell and/or electric powertrain liquid cooling systems a plus.
• Experience with integrating both proprietary technologies and new product development.
• Conversant with associated hardware such as heat exchangers, pipework, pumps, valves and sensors.
• Knowledgeable in experimental methods for thermodynamic and aerodynamic assessment.
• Experience in developing test instrumentation and data acquisition systems, knowledge of programming environments (e.g. LabVIEW) a plus.
• Experience of high voltage enclosures, power electronics and associated thermal management practices a plus.
• User of MATLAB Simulink/Simscape or similar 1D thermo-fluid software.
• Experience of commercial CFD codes (e.g. Ansys Fluent/CFX).
• Use of CAD (Siemens NX, Solidworks) for preparation of 3D model and engineering drawings, surface modelling a plus.
• Use of Teamcenter PLM or similar.
• Knowledge of materials, finishes and other processes including additive manufacturing.
• Commensurate depth of related aerospace industry experience.
• 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.
• Ability to work on own initiative as well as part of a growing multinational team.

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. Join us at our Global HQ in Cotswold Airport, home to some of our aircraft and the workplace of many ZeroAvians. Located just outside the historic market town of Cirencester, you’ll experience a workspace built by engineers for engineers. This is a high‑velocity and fast‑paced environment with good links to the M4 and M5, so it’s fitting that it’s also our UK Head Office.

Why Join Us?

• 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.

We also offer:

• 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.

Diversity and Inclusion

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.

Thinking about joining the aviation revolution? Why join us?