Mechanical Structural Analysis Engineer

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.

Engineering designs our next-generation hydrogen electric engines. Working across Hydrogen, Propulsion and Integration divisions, they solve technical problems and help decarbonize aviation by finding solutions for electric propulsion, hydrogen storage, fuel cell technology, power distribution, thermal management and more.

Role

Integrating a novel propulsion system within existing aircraft designs is an important opportunity in decarbonising aviation. To meet this challenge, ZeroAvia require an ambitious and capable Mechanical Structural Analysis Engineer to help deliver effective solutions for modifying and re-certifying aircraft.

The successful candidate will predominantly work on integrating ZeroAvia’s propulsion system onto airframe primary structures including understanding and mitigating against the impact the modifications have on the original aircraft type certificate. The candidate may also be involved in the structural verification of the powertrain and power generation system itself along with rig design.

Job responsibilities will include the design and analysis of aircraft mounting structures and structural assessment of primary aircraft structures to accommodate novel powertrain systems. The work will involve material selection, proposing solutions to achieve stress, stiffness, durability and damage tolerance requirements and weight and cost optimization. Strong experience with FEA is essential, as well as hand calculations. Experience in aircraft preliminary design and working on CS-23 certified or regional aircraft programs a benefit.

Must have a strong mechanical engineering experience and ability to work independently. Experience with complex components and assemblies. Experience with Aircraft and Automotive drivetrain systems a plus. Knowledge of FAA, EASA, CAA regulatory structures, rules, and regulations a plus.

Integrating a novel propulsion system within existing aircraft designs is an important opportunity in decarbonising aviation. To meet this challenge, ZeroAvia require an ambitious and capable Mechanical Structural Analysis Engineer to help deliver effective solutions for modifying and re-certifying aircraft.   

Job responsibilities will involve assessing and resolving the structural integrity of critical aircraft equipment including ZeroAvia’s bespoke fuel cell balance-of-plant solutions. The candidate may also be involved in structural analysis of aircraft structures along with rig design and therefore a curious mindset is essential for this role. 

Strong experience with FEA, as well as hand calculations is required. Experience in design and qualification of equipment is essential. Experience in designing equipment for mobility environments (aerospace, automotive, marine) is considered a benefit. 

Must have a strong mechanical engineering experience and ability to work independently. Experience with complex components and assemblies. Experience with Aircraft and Automotive drivetrain systems a plus. Knowledge of FAA, EASA, CAA regulatory structures, rules, and regulations a plus. 

Main responsibilities 

• Perform structural simulations and verification of powertrain equipment including test correlation. 
• Apply knowledge of materials (metallics and composites), finishes, welding, and other manufacturing processes to best meet product requirements. 
• Participate in design reviews. 
• Work closely with engineers, manufacturing and testing personnel to ensure that all aspects of the design are understood. 
• Serve as liaison with testing department for equipment qualification. 
• Provide expertise to review subcontractor design deliverables of critical aircraft equipment. 

Experience and qualifications 

Education: Bachelor’s degree or higher in an appropriate discipline and commensurate depth of related technical experience. 

Essential Requirements 

• High level of expertise in FE model creation and FE analysis.  
• Expert in one or more types of analyses: linear-static analysis, dynamic analysis, non-linear analysis. 
• Experience in ‘hand calculation’ analytical sizing analysis using industry standard methods. 
• Vibration and shock testing experience 
• Understanding of metallurgy, material models and failure modes. 
• Verification experience of computational/analytical models. 
• Comfortable working from first principles. 
• Good knowledge of design for manufacture and assembly 
• Working knowledge of Nx or Solidworks. 
• Tool and methodology development experience. 
• Excellent level of spoken and written English (additional languages a plus). 
• Excellent interpersonal skills, as well as good written and oral communication skills. 

Beneficial Requirements: 

• Proficient in Siemens Simcenter/NX Nastran. 
• DO160g testing experience 
• Proficiency in composite (FRP) design, sizing, and failure analysis including through FEA. 
• Vibration and noise analysis experience. 
• Experience in the creation of complex aerospace 3D CAD and mechanical engineering drawings. 

Knowledge of aerospace standards.  

Full product design life-cycle experience. 

Rig design and welding. 

Our solution-focused culture champions fast decision-making and empowers our people. We value results and efficiency and prioritise achieving our mission in the most effective and innovative way possible. We collaborate as a unified team to create solutions and solve problems, so we want people who share our principles to join us. 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.

Diversity and inclusion

As a young 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, colour, national origin, sex, gender expression, sexual orientation, age, marital status, veteran status, or disability status.

📈 Stock Options

🏡 Relocation support

🏖️ Holiday: 25 Days + Public Holidays

🍴 Kemble Location: Free Lunch

🔋 EV Club and Kemble Free EV Charging

🛩️ Flying Club: 5 free hours of flying lessons + Discount on Pilots License (PPL)

👩🏽‍⚕️ Private Healthcare: Plus Dental, Optical, Mental health support

💸 Salary sacrifice schemes: EV Club, Curry's Tech, Cycle to Work and Ikea Furniture

💰 Weekly Spot Bonuses

👩🏼‍⚖️ Income protection and Legal support