Hydrogen Fuel System Engineer

About the role

This role involves leading the design and development of hydrogen fuel systems for aircraft, encompassing both gaseous and cryogenic technologies. Key responsibilities include defining system architectures, managing component integration, and overseeing testing and validation processes. The engineer will ensure that all designs comply with aerospace regulations and safety standards, directly contributing to the company's goal of achieving zero-emission aviation.

The position requires supporting aircraft integration by specifying system layouts and component interfaces for onboard hydrogen systems. This includes managing relationships with suppliers to ensure technical compliance and timely delivery of components. Success in this role means driving design improvements and making informed technical decisions based on thorough system architecture and safety analyses.

A core aspect of the work involves defining and executing verification and validation strategies across various levels, from individual components to full systems. This includes hands-on experience with pressure testing and leak detection. The engineer will apply system safety methods like FHA, FMEA, and FTA, utilizing engineering tools to analyze performance and ensure the reliability of hydrogen fuel systems.

The salary for this position ranges from $60,000 to $90,000 USD annually.

Skills that matter here

• Mechanical Engineering: A foundational degree in this field is required, indicating the technical depth needed for designing complex gas systems.
• hydrogen: Direct experience with hydrogen systems, both gaseous and cryogenic, is essential for developing aircraft fuel systems.
• high-pressure environments: Expertise in managing systems under high pressure is critical for the safe and effective design of hydrogen storage and distribution.
• thermodynamics: Solid knowledge of thermodynamics is necessary for understanding and optimizing the behavior of hydrogen fuel systems.
• FMEA: Experience with Failure Mode and Effects Analysis is required for performing system safety and reliability assessments.
• CAD: Proficiency in CAD tools is expected for the design and modeling of hydrogen fuel system components and layouts.

Who this role suits

• A person with a strong background in gas systems, particularly hydrogen, who is eager to apply their expertise to the aviation sector.
• Someone who thrives in a role that combines hands-on testing with rigorous safety analysis and regulatory compliance.
• An engineer who enjoys leading design projects from concept through to validation, managing both technical details and external supplier relationships.
• An individual who is meticulous about safety standards and has a deep understanding of thermodynamics and fluid dynamics.

From the employer

• Lead the design and development of gaseous and cryogenic hydrogen fuel systems, including storage, distribution, and conditioning architectures.
• Support aircraft integration by defining system layouts, component packaging, and interfaces for onboard hydrogen systems.
• Manage supplier and partner relationships to ensure timely delivery and technical compliance of hydrogen system components.
• Define and execute verification, validation, and testing strategies across component, subsystem, and full system levels, including facility oversight.
• Perform system architecture, safety analysis (FHA, FMEA, FTA), and performance validation, driving design improvements and technical decisions.
• Ensure compliance with aerospace regulations, safety standards, and hazardous area practices (e.g. EASA/CAA, DO-160, ATEX, DSEAR).

• Degree in Mechanical Engineering (or related) with strong experience in gas systems, including hydrogen and high-pressure environments.
• Proven expertise in designing, integrating, and testing gaseous and cryogenic hydrogen fuel systems.
• Solid knowledge of thermodynamics, fluid/gas dynamics, and system performance analysis.
• Hands-on experience with pressure testing, leak detection (e.g. helium), and validation of fluid and vacuum systems.
• Experience applying system safety and reliability methods (FHA, FMEA/FMECA, FTA) and using engineering tools (e.g. ANSYS, MATLAB, Python, CAD).
• Strong understanding of hydrogen safety, cryogenic systems, and relevant regulatory frameworks; aerospace or transport sector experience is advantageous.

• 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 clubs – such as, running, cycling, padel, trivia, theatre and gardening.
• Stock options – so you can share in our success.
• 25 days holiday, plus public holidays and additional days awarded for long service – 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 and Cycle to Work.
• Weekly Spot Bonuses to reward excellence.
• Income Protection and Legal Support.