Thermal Design Engineer

As a Senior Thermal Systems Design Engineer, you will join our engineering team to support our activities within the aerospace sector. You will play a key role in the design and development of thermal management systems for advanced electric propulsion products, including electric motors, electronic control units, and complete Electric Propulsion Units (EPUs). Working at the forefront of electrification technology, you will combine expertise in thermodynamics, fluid mechanics, and heat transfer to develop innovative, manufacturable solutions that optimise performance, efficiency, and durability. - Location: Bicester - On Site: Hybrid - Clearance: Clearable - Experience Level: Senior (5-15 years of experience) Key Responsibilities: - Own the thermal system design for electric propulsion products and associated technologies - Develop thermal management solutions for motors, power electronics, and complete Electric Propulsion Units (EPUs) - Analyse and optimise sealed liquid cooling systems, including heat exchangers, pumps, coolant circuits, and airflow management - Perform thermal and fluid flow simulations to support product development activities - Validate analysis results against real-world operating conditions and provide engineering recommendations - Specify cooling system components, including pumps, heat exchangers, and airflow requirements - Support the development of innovative thermal management concepts to improve product performance and durability - Guide and support junior CAE Engineers, Designers, and Systems Engineers during the design process - Work closely with suppliers and customers to resolve technical challenges and deliver optimal engineering solutions - Ensure designs are suitable for assembly, manufacture, and volume production - Produce technical specifications, reports, and engineering documentation throughout the product lifecycle - Support testing and validation activities to verify analytical models and design assumptions Required Skills: - Strong background in thermal engineering, thermodynamics, fluid mechanics, and heat transfer - Experience designing thermal systems for complex engineering products - Practical understanding of electric machines, rotating equipment, or electromechanical systems - Experience with Computational Fluid Dynamics (CFD) and thermal analysis techniques - Proficiency with engineering analysis tools such as ANSYS Fluent or equivalent CFD software - Ability to assess complex engineering problems and develop practical, manufacturable solutions - Strong communication and stakeholder management skills - Experience working effectively within multidisciplinary engineering teams - Self-motivated and able to work independently with minimal supervision Required Qualifications: - A Bachelor’s or Master’s degree in Engineering, or equivalent military experience. - Proven experience delivering thermal design solutions for advanced engineering products - Experience supporting products through design, analysis, testing, and validation phases - Strong understanding of engineering development processes and product lifecycles Desirable Skills: - Experience within electric propulsion, electrification, electric vehicles, aerospace, or advanced mobility sectors - Knowledge of electric motor cooling and power electronics thermal management - Experience with Python, MATLAB, LabVIEW, or similar engineering software - Understanding of Design for Manufacture (DfM) and Design for Assembly (DfA) principles - Experience working with external suppliers and customers on technical development projects - Familiarity with physical testing and correlation of simulation results