Senior Mechanical Design Engineer

ZeroAvia is leading the transition to zero-emission aviation through the development of hydrogen-electric propulsion systems for civil and defence aerospace applications. As the world's only Design Organization Approved business focused exclusively on hydrogen-electric aviation, we have achieved significant flight test and regulatory milestones with the UK CAA and FAA and secured more than 3,000 pre-orders from airlines, OEMs and defence customers globally. Joining ZeroAvia means being part of a team pioneering the future of aviation and delivering lasting impact for the planet and its people.

As ZeroAvia advances towards certification and commercial deployment, the Senior Mechanical Design Engineer will play a key role in the design, development and delivery of critical mechanical systems and structures for our hydrogen-electric propulsion programmes. Combining technical leadership with hands-on design expertise, you will drive the creation of complex, certifiable and manufacturable engineering solutions while collaborating closely with manufacturing, test, certification and cross-functional engineering teams. You will also support technical reviews, mentor engineers and help establish engineering best practice as we scale our technology towards commercial operation. This is an exciting opportunity to influence the future of sustainable aviation and contribute to some of the most innovative aerospace programmes in the industry.

Requirements

Responsibilities

• Create, develop, and maintain complex 3D CAD models, manufacturing drawings, engineering documentation, and associated design data for mechanical components and assemblies.
• Apply sound mechanical engineering principles, including GD&T, material selection, manufacturing processes, and supporting analysis, to deliver robust, manufacturable, and compliant design solutions.
• Manage design data and configuration within the PLM system, ensuring all engineering outputs meet applicable quality, certification, and regulatory requirements.
• Collaborate with engineering, manufacturing, and external stakeholders to resolve technical challenges, support production activities, and ensure successful project delivery.
• Lead design reviews and technical sign-off activities, providing technical leadership, mentoring junior engineers, reviewing engineering deliverables, and holding or working towards engineering signatory approval authority.

Key Requirements:

• Degree in Mechanical Engineering or equivalent industry experience
• Minimum of 7 years' experience in mechanical design, preferably within the aerospace or other highly regulated industries.
• Advanced proficiency in 3D CAD, with Siemens NX preferred, including the creation of complex components, assemblies, and engineering drawings with a strong working knowledge of GD&T.
• Excellent knowledge of engineering materials, manufacturing processes, and configuration management within a Teamcenter PLM environment.
• Demonstrated ability to lead technical activities, draft, review and approve engineering documentation, mentor junior engineers.

Desirable Skills:

• Experience supporting aerospace certification programmes and compliance with relevant regulatory requirements.
• Knowledge of hydrogen, fuel cell, or propulsion system technologies.
• Experience of composite design and manufacturing methods.

Benefits

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 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.

We also offer:

• Stock options - so you can share in our success.
• 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.