Senior Mechanical Engineer - Assembly

About Commonwealth Fusion Systems:

Commonwealth Fusion Systems is on a mission to deliver the urgent transition to fusion energy.

Combining decades of research, top talent and new technologies, we’re designing and building commercially viable fusion power plants. And working with policymakers and suppliers to build the energy industry of the future.

We’re in the best position to make it happen. Since 2018, we’ve raised over $2 billion in capital – more than any other fusion energy company in the U.S.

Now we’re looking for more thinkers, doers, builders, and makers to join us. People who’ll bring new perspectives, solve tough problems, and thrive as part of a team.

If that’s you and this role fits, we want to hear from you.

Join the power movement as a Senior Mechanical Engineer - Assembly

As a Senior Mechanical Engineer on the Assembly Team at CFS, you design, develop, and manage fabrication of the wide variety of unique tooling needed for the successful assembly and integration of the SPARC tokamak device. This will entail the development of the overall concept, engineering, and use strategy of each tool assembly, and of the assembly step that the tool will facilitate. You will work closely and collaborate with the system teams to find the most efficient, creative, cost-effective, and safest way to manipulate, guide, and integrate each part of the larger tokamak system, design and build the tools needed, then finally write work-instruction packets that guide the use of the tool at the time of assembly. You will use your expertise on our most complex, largest, and most critical tools and manipulations, ensuring completion of the most challenging parts of SPARC assembly. You will guide and create how the giant parts of this multi-million pound “Swiss-watch” come together, and the mega-tools to do it! This work is conducted within a multi-disciplinary team of physicists and engineers as part of collaborative sponsored research projects at the MIT Plasma Science and Fusion Center and within CFS.

What you'll do:

• Ownership, design, and complete engineering development of the tooling, lifting, manipulation, and support frames for successful movement, handling, guidance, and integration of SPARC system components
• Formulate the general strategy for each assembly step utilizing these tools, as well active coordination and guidance of the system teams during parallel design activities for optimum assembly logic, steps, best practices, methods, strategies, and other details
• Analysis of the tool structures and kinematics to ensure that the tool can adequately and safely conduct the movement or support as designed
• Within the plan development, ensuring tool and personnel access is available as required for system assembly steps as outlined by the system owners
• Assist development for the alignment plan for precision placement for magnet and vessels by providing tools for successful handling and manipulation of parts to meet alignment requirements
• Responsible for the plans for part movement at each step and ensuring no interferences with other systems during movement
• Oversight over fabrication of the tools at outside vendor shops, with guidance and troubleshooting to ensure the tool is built to the specifications required
• Specification and procurement of all purchased hardware required for the tools
• Responsible for the assembly work instruction packets for each tool, to be used during the assembly phase of SPARC, as well as the assembly, proofing, and activation of the tools in your ownership on-site
• Work with other tooling engineers, designers, and assembly package coordinators, as well as direct personnel performing the Tokamak Assembly during on-site work in the use of your tool and related assembly step
• Work with teammates in a collaborative fashion to receive feedback early and often to ensure all requirements are met. Many SPARC projects involve high loads, vacuum requirements, and complex manipulation requiring the involvement and review of adjacent sub system experts.

What we’re looking for:

• Civil, Structural, Mechanical, or Aerospace Engineering B.S
• 3 to 5 years of Mechanical Engineering Experience demonstrating project ownership and construction of metallic structures
• At least 3 years technical experience in the fabrication and integration of complex and large mechanical structures (e.g. aerospace, mechanical, chemical)
• Experience with standard actuation and guidance mechanisms and tools
• Experience with finite element analysis
• Lifting operations experience (>10 Tons)

Bonus points for:

• Civil, Structural, Mechanical, or Aerospace Engineering M.S
• 5+ years of Mechanical Engineering Experience demonstrating project ownership and construction of metallic structures
• At least 5 years technical experience in the fabrication and integration of complex and large mechanical structures (e.g. aerospace, mechanical, chemical)
• 4+ years experience with multiple actuation and guidance mechanisms and tools
• 4+ years experience with finite element analysis
• Lifting operations experience (>50 Tons), with additional complex handling (rotations)
• Experience with metrology, high-vacuum processes, leak checking, tool sourcing and development, NX
• Knowledge of welding and fabrication of large welded structures
• Knowledge of machining processes and best practices
• Knowledge of bolted joints and flanges
• Knowledge of common methods of actuation and movement
• Finite-Element Analysis experience (ANSYS preferred)
• Creative and imaginative problem solving
• Exceptional attention to detail
• Safety conscious and proactive
• Ability to clearly express and critique ideas
• Aptitude to use data to drive decisions
• An emphasis on elegance and simplicity over complexity
• The ability to thrive in fast-paced, dynamic environments

Must-have Requirements:

• Ability to occasionally lift up to 50 lbs
• Perform activities such as typing, standing, stooping, climbing or sitting for extended periods of time
• Willingness to travel or work required nights/weekends/on-call occasionally
• Work in a facility that contains industrial hazards including heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, high current, pressure systems, and cryogenics