As a Motor Thermal design Engineer at ZeroAvia, you'll play a crucial role in designing, developing and optimizing thermal aspects of hydrogen-electric powertrains. You'll collaborate with a multidisciplinary team of thermal, aerodynamics and turbomachinery engineers to create efficient, reliable, and high-performance thermal solutions for aviation applications.

Reporting to the Head of Aerothermal design you will contribute, within an integrated project team, on all aspects of our electric motor thermal design. This includes; 1D and 3D analyses of the rotor, stator and housing thermal performance, definition of thermal interfaces, selection and development of thermal system components such as pumps, filters and sensors. In collaboration with our System Test Team define, execute and analyse data from thermal tests at sub-component and full assembly level. Leverage test data to validate models and incorporate learnings into working with our Systems Engineering team to define, validate and verify equipment requirements relevant to thermal aspects of the design.

ZeroAvia is pioneering the shift towards sustainable aviation with hydrogen-electric powertrains, aiming to make air travel truly clean. We have a vision, for not just cleaner skies but also for revolutionizing how the aviation industry approaches technology.

We are focusing on:

• Designing and commercializing hydrogen-powered solutions for aviation.

• Fostering a culture of innovation, efficiency, and problem-solving within a high-velocity work environment.

• Encouraging team members to take radical ownership and challenge conventional approaches to drive innovation.

If you're interested in contributing to this mission, ZeroAvia looks for individuals who are:

• Solution-focused and driven by results.

• Eager to ask questions and challenge existing norms.

Committed to innovation, with the goal of zero-carbon aviation for a sustainable future.

Key Responsibilities

• All aspects of electric motor thermal design including analysis, test and verification

• Collaborate with mechanical, electromagnetics and systems engineering teams to develop innovative thermal management concepts and designs

• Develop thermal and fluids models for electric motor thermal management and lubrication including;

• Hand calculations pertinent to thermofluids design

• 1D thermal/fluid network analyses

• Conjugate CFD analysis

• Define strategies for experimental validation of thermal analyses at sub-component and full assembly level

• Liaise closely with internal stakeholders to define, validate and demonstrate compliance to equipment, powertrain and certification requirements

• Prepare technical reports in support of requirements validation and demonstration of compliance

• Specification and delivery of relevant equipment such as pumps, filters, sensors and fluid conveyance

• Contribute to the development of ZeroAvia modelling methodologies, best practices and design standards

Qualifications & Experience Required:

• Bachelor’s Degree in Aerospace or Mechanical Engineering
• Minimum 5 years industry experience as a Thermal Engineer or similar
• Knowledge of key principles of electric motor design such as electromagnetics, rotor dynamics, motor architectures and manufacturing methods
• Proven application thermal analysis methods with specific application to electric motor design
• Experience in Matlab, Simulink & Simscape
• Experience with motor design softwares (e.g. MotorCAD)
• CFD experience including conjugate heat transfer(preferentially using StarCCM+)
• CFD experience including moving reference frame (MRF) modelling (prefentially using StarCCM+)
• Experience with experimental methods & equipment relevant to motor thermal characterisation
• Demonstrable experience of design to requirements, preferentially within an aerospace context
• Competency in the use of CAD and PLM software (preferentially Siemens NX and TeamCenter)
• Awareness of high voltage systems, power electronics and Hydrogen fuel cells a plus
• Hazardous Area Voltage (HAV) trained
• 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 an integrated project team
• Able to travel internationally on occasion

Physical Requirements

• This role is primarily office/lab- based with occasional movement around test facilities.
• Must be able to work at a desk and move between office environments.

Why Join Us?

We want to help you be your best self, at work and at home, that’s why we provide our employees with…

• 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 fueled 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.

We also offer:

• Stock options – so youcan share in our success.
• 5 hours of free flying lessons
• 25 days holiday, plus public holidays – 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, Cycle to Work, and Ikea Furniture.
• 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.