Senior Mechanical Engineer - ZeroAvia

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. 

You will become a solution-focused champion in our high-velocity culture. We value results and efficiency and prioritise achieving our mission most effectively and innovatively possible. You’ll be part of our unified team to create solutions and solve problems, If you’re eager to take radical ownership and are unafraid to ask questions or challenge the status quo, then we want you to be part of our Clean Sky Thinking. 

ZeroAvia’s powertrain development focuses on tightly integrating H2 Fuel Cell power systems and storage, along with electric drivetrain components, to deliver a unified solution that is both environmentally friendly and economically superior to traditional aircraft drivetrain solutions. 

ZeroAvia is seeking a highly motivated Mechanical Engineer or Senior Mechanical Engineer to join our electric propulsion system team. In this role, you will design and analyze parts and assemblies for aerospace electric propulsion motors and their adjacent systems. You will create, manage, and release CAD models, drawings, and other controlled files within the company PLM system in accordance with company and industry standards. You will evaluate designs and materials for compliance with environmental testing and regulatory requirements as set by aviation authorities. You will proactively grow your knowledge base while working with a diverse group of multidisciplinary engineers to develop, prototype, test, and produce world-class electric propulsion systems for the aviation industry. 

Requirements

• Create CAD models and GD&T drawings of parts and assemblies for electric aviation motors and surrounding systems. 
• Work with team members to review and release designs for prototype and production, applying knowledge of materials, fits, finishes, and manufacturing methods as appropriate. 
• Perform simulation and analysis as required to support design and certification efforts, both numerical and analytical, including structural, modal, thermal, and fluidic. 
• Propose, design, and build test stands as required to support design efforts and qualification, and execute test plans in accordance with company safety requirements and industry best practices. 
• Define production and assembly processes for electric aviation motors and their subcomponents and parts. Design and/or evaluate assembly aids for motor builds as needed. Support manufacturing engineering in the creation of work instructions for series production. 
• Collaborate closely with cross-functional teams, including electromagnetic, power electronic, thermal, and aerodynamics engineers, to incorporate motor systems seamlessly into our aviation platforms, considering factors such as system integration, electromagnetic compatibility, and operational safety. 
• Participate in design reviews, requirement reviews, test readiness reviews, and other reviews and assessments as required to support aerospace certification. 
• Serve as a liaison with operations and outside suppliers during manufacture of parts and subcomponents to ensure that all design issues are resolved, and that drawings are updated as required. 
• Disposition non-conforming parts and components. 
• Other tasks as defined by line manager. 
• Excellent interpersonal skills, as well as good written and oral communication skills. 
• Excellent level of spoken and written English (additional languages a plus). 
• Ability to work on own initiative as well as part of a small team 
• Have the ability to assimilate technology and technical details quickly and communicate the requirements clearly to ZeroAvia colleagues and stakeholders 
• Demonstrate care and trust for your colleagues in your professional work and working environment 

Experience:

• For Mechanical Engineer, Bachelor’s degree in appropriate field (Mechanical Engineering, Aerospace Engineering, etc.) and professional experience of 2 or more years, or an equivalent combination of education and experience. For Senior Mechanical Engineer, Bachelor’s degree in appropriate field (Mechanical Engineering, Aerospace Engineering, etc.) and professional experience of 6 or more years, or an equivalent combination of education and experience. 
• NX or similar CAD software – solid modelling and drawing creation with GD&T 
• Teamcenter PLM or similar configuration management  
• Simcenter 3D, Nastran, or similar structural FEA software 
• Design and analysis of metallic, thermoplastic, thermoset, elastomeric, and composite parts including fatigue cycling, thermal effects, structural loading, and frequency-domain effects 
• Knowledge of production methods for the above, including subtractive, additive, finishing, heat treatment, and coatings 
• Knowledge of production methods for electric motors, including lamination stacking, coil windings, varnishing, potting, and magnet bonding 
• Design and analysis of gears, splines, and similar geometries 
• Design for reliability and fault tolerance 
• Design for aerospace certification per Part 23, Part 33, DO160G, and other applicable guidelines or regulations from FAA, CAA, and/or EASA 

Benefits

The wage scale or salary range for this position is between $90,000 - $130,000. In addition to the foregoing base compensation, additional compensation and benefits are available to employees and eligible family members (as applicable) including the following:

 Bonus: Annual discretionary bonuses.

 Equity: Ability to exercise company stock options

 Retirement: Eligible to participate in the company's 401(k) Plan, with up to a 4% matching

‍⚕️ Health Insurance: Employer covers up to 80% of the employee's monthly premiums on medical, dental, and vision.

 Life Insurance: Basic Life/AD&D of up to $50,000 and the option to add on Supplemental Coverage.

 Short-Term Disability: Up to 60% of your earnings for up to a period of 24 weeks.

 Long-Term Disability: If your disability extends beyond 180 days, LTD Coverage for up to 60% of your earnings.

️ Paid Time Off: Eligible employees may accrue up to 120 hours per year (15 days) and may borrow up to 40 hours (5 days).

 Sick Time: Eligible employees may accrue up to 40 hours, per year (5 days)

️ Paid Holidays: 12 observed holidays, per calendar year.

️ The Fly Club: up to $2,000 of reimbursement towards flying lessons to all full-time staff

Please note, among other factors, the compensation offered may vary based on work location, experience, qualifications, specialties, training, and then-current market and business considerations