Senior Mechanical Design Engineer

We are seeking a highly skilled Senior Mechanical Design Engineer to create, own, and maintain complex mechanical designs and CAD data, working closely with cross-functional engineering teams. This role is suited for a confident, independent engineer with deep expertise in 3D CAD, strong understanding of GD&T, and the ability to lead technical discussions and guide junior colleagues. 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.

Requirements Responsibilities:

• CAD Design & Ownership: Full ownership of CAD design and associated data for assigned components and assemblies. Create detailed 3D CAD models of complex parts and assemblies (NX preferred). Produce high-quality 2D production drawings conforming to ASME standards and all applicable regulatory requirements. Maintain CAD and engineering assets within the PLM system (Teamcenter or similar). Provide CAD design solutions for technical challenges across multiple projects.
• Engineering & Analysis: Apply strong understanding of GD&T, materials, finishes, and manufacturing processes. Use knowledge of stress analysis principles to assess structural implications of design decisions. Conduct supporting simulation or analysis activities as needed (mechanical, stress, thermal, or fluid). Ensure designs meet aerospace regulatory standards where applicable.
• Cross-Functional Collaboration: Participate in and lead relevant design reviews. Work closely with engineers, external teams, and manufacturing personnel to ensure full understanding of design intent. Serve as liaison with operations during part manufacture, ensuring timely resolution of design issues and updating drawings where required.
• Leadership & Mentoring: Guide junior team members on design best practices, documentation, and engineering processes. Technically direct work and check drawings prepared by less experienced engineers. Act as a focal point for mechanical design within assigned projects, driving progress and leading discussions.
• General Responsibilities: Quickly assimilate new technologies and communicate technical requirements clearly to internal stakeholders. Demonstrate diligence, flexibility, and a results-focused mindset.

Experience & Qualifications:

• Degree in Mechanical Engineering
• Minimum of 7 years industry experience
• Expert user of 3D CAD with NX strongly preferred.
• Strong understanding of GD&T (ASME).
• Experience with Teamcenter PLM or similar systems.
• Knowledge of materials, finishes, and relevant manufacturing processes (including additive manufacturing).
• Experience with fuel-cell-related systems (advantageous).
• Capable of creating complex aerospace grade CAD models and mechanical drawings.

Engineering Skills:

• Ability to independently check/sign drawings or be close to achieving checking status.
• Experience writing high quality technical reports across a variety of engineering topics.
• Understanding of stress analysis and its impact on mechanical design decisions.
• Familiarity with relevant engineering processes and ability to guide junior engineers in their use.

Benefits:

At ZeroAvia, we are 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 are 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 will 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 is fitting that it is 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 subsidised 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.

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.