Role Overview

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.

Main Responsiblities

• Create CAD models and GD&T drawings of parts and assemblies for electric aviation motors/power inverters 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/inverter builds as needed. Support manufacturing engineering in the creation of work instructions for series production.

• 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.

• 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 and packaging for power inverters including power modules, bus laminations, heat exchangers, PCBA development and interconnections.

• 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

Who are we?

ZeroAvia is pioneering the shift towards sustainable aviation with hydrogen-electric powertrains, aiming to make air travel truly clean. 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 is looking for individuals who are:

Solution-focused and driven by results.
Eager to ask questions and challenge existing norms.
Committed innovation, with the goal of zero-carbon aviation for a sustainable future.

We have a vision for not just cleaner skies but also for revolutionizing how the aviation industry approaches technology.

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 at the front of mind with our trained Mental Health First Aiders, Employee Assistance Programmes and wellbeing support.
• 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:

The wage scale or salary range for this position is between $150,000- $160,000. In addition to the foregoing base compensation, additional compensation and benefits are available to employees and eligible family members (as applicable), including the following:

• 📈 Equity: Ability to exercise company stock options
• 👵🏽 Retirement: Eligible to participate in the company's 401(k) Plan, with up to a 4% matching. With immediate vesting after 90 days of employment.
• 👩🏽‍⚕️ Health Insurance: The company will sponsor 85% of the premium cost for eligible employees and 65% of the premium cost for eligible dependents with Cigna plans.
• 🧬 Life Insurance: The company covers up to $50,000 and offers the option to add on supplemental coverage.
• 🛩️ Dental and Vision: ZeroAvia provides 80% of the employee premium and 50% of the premium for dependents.
• 💫 Short-Term Disability: Up to 60% of your earnings for up to 24 weeks. The company pays for the premium on your behalf.
• 🤒 Long-Term Disability: If your disability extends beyond 180 days, you have LTD Coverage for up to 60% of your earnings. The company pays for the premium on your behalf.
• 🏖️ Paid Time Off: Eligible employees may accrue up to 120 hours per year (15 days) and may borrow up to 40 hours (5 days). With one extra day granted after each year of employment.
• 🩺 Sick Time: Eligible employees may accrue up to 40 hours per year (5 days)
• 🛩️Mental Health: EAP with six therapy sessions, designated mental health first aiders, and a ZeroAvia Wellness Hub with additional resources.
• 🏖️ Paid Holidays: 12 observed holidays per calendar year.
• 🛩️ The Fly Club: Five hours of flight lessons covered up to $1,500 and a discounted path to get a Private Pilots License.
• 🛩️Maternity and Paternity Leave: ZA offers generous paternity pay and leave allowance, which is more than any state entitlement.
• 🛩️Global Compassion Leave: Up to 10 days paid leave to take care of dependents with applicable life circumstances.
• 🛩️ Additional Benefits: Intellectual property bonus, Travel Insurance, Quarterly and biweekly spot bonuses. Soccer club. Strava Club. Referral bonus. Happy hours. Winter Party.
• 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

Commitment to Diversity and Inclusion

At ZeroAvia, we value diversity and believe that different backgrounds and perspectives foster originality and creativity. We are an equal opportunity employer and do not discriminate based on race, religion, color, national origin, sex, gender expression, sexual orientation, age, marital status, veteran status, or disability status.

Join us in leading the way to a sustainable aviation future. Apply today and become a part of our visionary team at ZeroAvia!