As an Advanced Mechanical Design Engineer (Thermal Runaway), you will join the Energy Storage team at Vertical Aerospace, focusing on thermal runaway prevention, mitigation and containment for the Valo eVTOL aircraft. You will support thermal runaway testing, analyse test data, and translate insights into mechanical designs, simulations and qualification strategies. This role is critical to battery safety and certification, involving collaboration with stress, manufacturing, and test teams to deliver certifiable designs.

Responsibilities

Support and progress thermal runaway testing activities at cell, module and pack level
Analyse thermal runaway test data to guide simulation, design, manufacturing and future test activity
Develop and own mechanical designs and mitigation concepts related to thermal runaway containment
Work closely with stress, manufacturing, quality and test teams to deliver compliant, certifiable designs
Support the definition of verification and qualification strategies, balancing test coverage with certification requirements
Contribute to the qualification of novel materials and processes for battery safety applications
Own at least one thermal runaway–related commodity through design, test and Critical Design Review
Produce high-quality CAD, drawings and PLM data using Dassault 3DX / CATIA
Support key Energy Storage milestones including Battery CDR (Q3 2026)

Requirements

Mechanical design experience within complex electro-mechanical systems (battery systems highly desirable)
Understanding of thermal runaway prevention, mitigation and/or containment methods (a strong differentiator, not a prerequisite)
Experience with thermal runaway testing and/or simulation at cell, module or pack level is highly desirable
Strong understanding of structural, thermal, electrical and manufacturing considerations for HV battery packs, ideally with cylindrical cells
Knowledge of regulated engineering environments; aerospace qualification and certification experience is advantageous
Strong CAD and PLM capability, ideally using Dassault 3DX and CATIA
Experience working in fast-paced engineering teams with evolving processes
Familiarity with DFMEA, GD&T and engineering best practice (ISO GPS / BS8888)
Degree in Mechanical, Aerospace or a related engineering discipline

Nice to have

Experience contributing to qualification or certification test programmes
Exposure to novel materials or high-rate automated manufacturing processes
Experience in aerospace, automotive, motorsport, defence or energy storage
Working towards Chartered Engineer (CEng) status

Benefits

26 days holiday, plus bank holiday
5 extra days per year to buy (or sell)
5 extra days holiday when you get married or enter a civil partnership
Additional 4% of your salary to spend on extra benefits
Award-winning digital health and wellbeing service (Help@Hand)
Company performance based bonus - rewarding company and individual performance
Company Share Scheme - open to every Vertical employee
Company Pension Scheme - 5% and we match it
Breakfast on us, every day