CFD & Simulation Engineer

Role overview

We are looking for an experienced CFD & Simulation Engineer to run aerodynamics and CFD studies, build and validate simulation environments, and support SITL and HITL testing. The role covers aerodynamic and thermal analysis, simulation model development, virtual testing, and correlation of predictions with field test data.

What you'll do

Aerodynamics & CFD

• Run parametric CFD studies (OpenFOAM, ANSYS Fluent or Star-CCM+) on body geometry, fairing profiles and structural cross-sections to minimise drag while preserving structural margins
• Characterise propulsion-body interactions: wake interference in compact layouts, asymmetric loading at steep angles of attack, and performance variation across operating speed ranges
• Model altitude-dependent aerodynamic performance, including air density variation from sea level to 5,000 m and its effect on drag, propulsive efficiency and range
• Perform thermal CFD analysis for onboard electronics and power source cooling under sustained high-power operation in compact, sealed enclosures
• Validate CFD predictions against field test data by correlating predicted vs measured drag, power draw and energy consumption
• Drive aerodynamic shape optimisation using adjoint methods, surrogate models or parametric sweeps

Simulation & Virtual Testing

• Build and validate Gazebo simulation environments with accurate aerodynamic models, propulsion dynamics and sensor noise models
• Integrate SITL frameworks so guidance and control engineers can test autonomous algorithms without field tests
• Develop scenario libraries covering engagement geometries, speeds, altitudes and environmental conditions (wind, turbulence, density variation)
• Design HITL test bench specifications that connect real embedded hardware to the simulation physics engine
• Create automated regression test pipelines that run algorithm changes against the scenario library and flag performance regressions
• Keep simulation fidelity high by continuously updating aerodynamic and propulsion models as new test data arrives

What you'll need

• Demonstrated experience with ROS 2 and Gazebo (Classic or Harmonic), including custom plugin development for aerodynamic and propulsion models
• Strong Python and C++ skills for simulation scripting, data analysis, post-processing and plugin development
• Understanding of propulsive aerodynamics: blade element theory, performance variation with operating conditions, wake interaction effects
• Ability to process and interpret test data: sensor logs, power telemetry and position traces
• 3+ years of hands-on CFD experience in external aerodynamics, including mesh generation, turbulence modelling and validation against wind tunnel or test data
• B.Tech or M.Tech in Aerospace Engineering, Mechanical Engineering or Computational Fluid Dynamics

Nice to have

• Work on high-speed UAV or munition aerodynamics, especially where compressibility corrections matter
• Propeller or rotor CFD experience: rotating reference frames, actuator disk models or blade-resolved simulations
• Familiarity with PX4 SITL integration and MAVLink
• Background in design optimisation: adjoint methods, Bayesian optimisation or multi-objective evolutionary algorithms
• Hands-on rapid prototyping (3D printing, CNC, composite fabrication) for aerodynamic validation articles