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Materials Engineer
ZeroAvia
Kemble, Cirencester GL7, UK
Posted on Oct 8, 2025
Role Overview
We are seeking a highly motivated Materials Engineer to support the development and optimization of advanced materials used in hydrogen fuel cell systems, electric propulsion components, and aircraft structural elements. Choosing, qualifying, and managing the materials (metals, composites, and polymers) used in our aerospace products—ensuring they meet performance, cost, manufacturing, reliability, environmental, and certification standards. Provide approved material limits, process guidelines, and material histories that can withstand review by customers, regulatory authorities, and others.
Key Responsibilties
- Material selection & allowables: generate/release material and process specifications/qualification; define A/B-basis allowables for metals and S-basis for composites where applicable. Create design data sheets with mechanical, thermal, electrical, flammability, fatigue/fracture, corrosion, and environmental properties (dry/wet/hot/cold, DO-160G conditions).
- Certification & compliance: build substantiation packages traceable to SAE/AMS/ASTM, MMPDS, CMH-17, and internal test reports. Define qualification plans (coupon → element → subcomponent → component) aligned to AC/CS guidance and customer spec.
- Manufacturing & DFx partnership: approve processes: forging, casting, heat treatment, machining, forming, bonding, curing, welding/brazing, AM/HIP. Design/approve process control documents (PCDs), traveler checkpoints, and acceptance criteria; design FAI and control plans.
- Reliability, durability, and safety: own fatigue/fracture control plans; corrosion prevention & control; damage tolerance for metals and composites (including CAI and barely visible impact damage). Define inspection intervals and NDI/NDT methods (UT, RT, PT, MT, EC; POD/false call management).
- Supplier & pedigree management: qualify mills, pre-preggers, heat treaters, platers, bond shops, AM bureaus; verify AS9100/NADCAP. Create receiving inspection standards, lot acceptance testing (LAT), and CoC/traceability requirements.
- Test strategy & data management: plan and oversee coupon/element testing; manage labs; ensure statistical treatment (A-/B-basis, confidence levels). Maintain a single source of truth for material data and revision control; drive digital threads to CAD/FEA/PLM/ERP.
- Problem solving: lead MRB for material-related NCs; run root cause (5-Why/Fishbone/DoE); implement CAPAs.
- Cross-functional enablement: train design, stress, and manufacturing teams on proper material use, environmental limits, and handling/processing.
- MS/BS in Materials Science/Metallurgy/Polymer/Composites with proper aerospace experience (7+ years)
- 7+ years in aerospace materials engineering (OEM or Tier-1), covering both metals and composites.
- Demonstrated ownership of A/B-basis allowables, CMH-17 methods, and qualification test programs.
- Hands-on with heat treatment, bonding, autoclave/RTM, welding/brazing, AM post-processing, and surface finishing.
- Experience with NDI/NDT planning and NAS-410/NADCAP audits.
- Strong statistics (DOE, regression, distribution fitting, tolerance analysis).
- Hydrogen systems or high-voltage propulsion exposure (compatibility, insulation, EMI/ESD).
- Familiarity with export controls and controlled data handling.
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 fueled 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 youcan share in our success.
- 5 hours of free flying lessons
- 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.