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.

Zero Avia 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 power plant 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 managements 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 Zero Avia 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 Zero Avia, 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…