Senior Manufacturing Engineer

ZeroAvia is pioneering the transition to zero-emission aviation through the development and certification of hydrogen-electric propulsion systems. Our technology combines hydrogen fuel cells, electric motors, advanced power electronics, and aerospace-grade systems integration to power the next generation of sustainable aircraft. As we accelerate towards certification and commercial deployment, we are seeking an experienced Senior Manufacturing Engineer to lead manufacturing development activities within a highly dynamic, prototype-intensive environment. Position Summary The Senior Manufacturing Engineer will be responsible for developing, implementing, and continuously improving manufacturing processes for ZeroAvia's hydrogen-electric propulsion systems. The role requires a hands-on engineer who thrives in an environment where designs evolve rapidly, build schedules are challenging, and close collaboration with engineering teams is essential. The successful candidate will bridge the gap between Design Engineering and Production, supporting rapid prototyping, technology maturation, certification hardware builds, and the industrialisation of future production systems. This is a key role supporting the transition from concept and development builds to low-rate production and ultimately certified aerospace products. Key Responsibilities Lead manufacturing activities across prototype, development and certification programmes, supporting system integration, testing and flight-test activities whilst driving rapid resolution of manufacturing challenges. Develop, validate and optimise manufacturing processes, assembly methods, work instructions and manufacturing documentation to ensure safe, efficient and scalable production of complex aerospace systems. Act as the manufacturing lead within product development teams, influencing design decisions through Design for Manufacture and Assembly (DFMA) principles to improve quality, cost, manufacturability and performance. Drive industrialisation and production readiness activities, including manufacturing strategy development, tooling and equipment specification, process validation and capacity planning to support the transition from development to serial production. Ensure compliance with aerospace quality and regulatory requirements, supporting process qualification, first article inspections, audits, root cause investigations and certification activities. Lead continuous improvement initiatives and collaborate across Engineering, Quality, Supply Chain and Production teams to enhance productivity, reduce waste, improve build quality and support strategic manufacturing objectives. Role Requirements Degree-qualified in Manufacturing, Mechanical, Aerospace, Industrial Engineering or a related discipline, with a minimum of 7 years' manufacturing engineering experience within aerospace, defence, motorsport, advanced energy or other highly regulated industries. Proven experience supporting prototype and development programmes, introducing new products from concept through production and developing manufacturing processes for complex electro-mechanical assemblies. Strong technical knowledge of aerospace manufacturing, assembly processes, precision machining, process validation, configuration control, engineering change management, and production tooling and fixture design. Ability to interpret engineering drawings, CAD models, specifications and bills of materials, with experience using ERP/MRP systems and manufacturing planning tools. Working knowledge of aerospace quality and certification requirements, ideally within AS9100 and Part 21 environments, with experience in advanced technologies such as hydrogen fuel cells, electric propulsion, battery systems or power electronics considered advantageous. Excellent problem-solving, communication and stakeholder management skills, with a hands-on approach, continuous improvement mindset and the ability to thrive in a fast-paced, high-growth engineering environment. 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 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. We also offer: 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 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.