Mechanical Design Engineer

ZeroAvia is a leader in zero-emission aviation, flying the world’s largest hydrogen-electric aircraft since September 2020. Its focus is the design and commercialization of hydrogen-powered aviation solutions to address a variety of markets, initially targeting short-haul, sub-regional commercial flights up to 500 miles. To date, ZeroAvia has secured the UK CAA and FAA experimental permit to fly for its 6 seat aircraft powered by hydrogen-electric powertrain, passed significant flight tests, and is on track for commercial deliveries by 2023. Its achievements to date were rewarded by the UK prime minister by inviting ZeroAvia as a member to the UK Jet Zero Council.

ZeroAvia’s powertrain development focuses on integrating hydrogen storage tanks, fuel cell systems, and electric motors, delivering a solution that will be not only without carbon emissions but also cheaper to operate. Commercialising the solution requires the establishment of a new clean aviation ecosystem, encompassing hydrogen production from renewable energy sources and tackling public perception of safety.

Role Overview

The Fuel Cell Design team at ZeroAvia is designing the next generation of high-temperature fuel cell stacks based on the company’s proprietary turbo air-cooled technology; delivering high specific power while providing high reliability and safety.

The main objective of the team is to design state-of-the-art hardware that will be installed on different types of aircraft including, but not limited to, fixed-wing and rotorcrafts. Being a part of this team, you will be responsible for the mechanical design of different parts and assemblies that form the fuel cell stack. This role requires the desire to be involved in the whole spectrum of engineering activities including requirements definition, CAD design, tolerance study, simulation, testing and evaluation.

Main responsibilities

• Work in a start-up team environment to analyze requirements from customers and assist in developing fuel cell system design solutions;
• Assist in developing and documenting fuel cell system requirements, including interface and performance requirements;
• Use structured processes to design new mechanical parts, assemblies, and installations of components of fuel cell energy systems under deadlines with a high-performing start-up team;
• Establish structural specifications, performs stress analysis and other engineering design evaluations;
• Perform functional analyses, when applicable, and mass, power, and sizing structural analyses;
• Produce engineering drawings, reports, BOMs and other types of technical documentation;
• Provide engineering checks of data produced by peer groups or other project participants;
• Perform developmental testing and evaluation of the designed component;
• Interface with customers, suppliers, and other project stakeholders.

Experience and qualifications

• Bachelor’s Degree in Aeronautical, Mechanical, or related engineering field;
• Must have at least five years of experience performing design engineering functions in aeronautical, automotive, or similar industries;
• Must have knowledge of relevant production processes and materials (metal forming, machining, 3d printing, sheet metalwork, die-casting, electroplating, etc);
• Hands-on work in assembling, evaluating, and testing electro-mechanical subsystems;
• Proficient in 3D solid modelling, preferably Solidworks or Siemens NX;
• Proficient in understanding and applying GD&T requirements to new designs;
• Able to read and understand complex drawings;
• Proficient with manual stress calculations as well as linear FEM stress analysis;
• Proficiency in MS Office (Word, Excel, PowerPoint, Visio);
• Tech savvy;
• Excellent communication skills;
• Thrives under a dynamic, milestone-oriented work schedule.

Diversity and inclusion

ZeroAvia is an equal opportunity employer and as a young company in the aviation industry, we value diversity and need people of different backgrounds that bring a plethora of skills, perspectives, and mindsets to the table that can spur originality, imagination, and creativity. We do not discriminate based on race, religion, colour, national origin, sex, gender expression, sexual orientation, age, marital status, veteran status or disability status.