Controls Development Engineer

Helion; Everett (WA); On-site; USD 164,000 - 200,000; Full time

Benefits offered by this job

Medical, Dental, Vision plans

31 Days of PTO (vacation + sick)

10 Paid holidays + winter break

401(k) match up to 5%

Disability and life insurance

Parental leave and support

Wellness stipend

Job summary

Helion, based in Everett, WA, seeks a Manufacturing Automation and Controls Engineer to design, scale, and launch production equipment onsite. You will develop automation system architecture, integrate electrical schematics with MES, and drive safety compliance for high-volume manufacturing.

You will work with Fanuc and KUKA robotics, and partner with production and supply chain to optimize uptime and efficiency. This role reports to the Factory Development Manager in Everett.

Qualifications

• Bachelor’s degree in engineering with 5+ years of experience in manufacturing controls.
• Proficient in electrical schematic design and PLC programming.
• Experience programming industrial robots (Fanuc and KUKA).
• Designing safety systems for automated machines and risk mitigation.
• Apply physics-based first principles to challenge design requirements.
• Strong cross-functional communication with production and supply chain.

Responsibilities

• Design, scale, and launch manufacturing equipment with automation architecture for multiple production lines.
• Produce electrical diagrams and integrate with MES; set up reporting to track OEE and critical data.
• Collaborate to develop and improve testing processes and understand pulsed power circuit integration.
• Coordinate with machine suppliers for design reviews and equipment buyoff.
• Implement ANSI, ISO, and OSHA-compliant safety systems for high-volume manufacturing.
• Troubleshoot equipment, identify root causes, and implement long-term uptime improvements.

Skills

Electrical schematic design

PLC programming

Robotics programming

Safety systems design

First principles engineering

Cross-functional collaboration

Education

Bachelor’s degree in engineering

Tools

Allen-Bradley PLCs

Siemens PLCs

Fanuc robotics

KUKA robotics

Job description

About Helion

We are a fusion power company based in Everett, WA, with the mission to build the world's first fusion power plant, enabling a future with unlimited clean electricity. Our vision is a world with clean, reliable, and affordable energy for everyone.

Since Helion's founding in 2013, we have raised $1.5 billion from long-time investors such as Sam Altman, Mithril, and Capricorn Investment Group as well as new investors including Thrive Capital, LightSpeed Venture Capital, SoftBank, and others to propel us forward. Our current prototype, Polaris, has reached record-breaking plasma temperatures of 150 million degrees Celsius (13 keV). Helion is continuing to iterate and on the path to the world's first fusion power plant, Orion. This is a pivotal time to join Helion. You will tackle real-world challenges with a team that prizes urgency, rigor, ownership, and a commitment to delivering hard truths – values essential to achieving what no one has before. Together, we will change the future of energy, because the world can't wait.

What You Will Be Doing

You will develop, implement, and standardize automation and controls used in manufacturing Helion’s fusion generators. By building in-house expertise in our manufacturing processes, you will help accelerate the transition from rapid prototyping to mass production—advancing Helion’s mission to provide clean electricity for the planet. This is an onsite role that reports directly to the Factory Development Manager at our Everett, WA office.

You Will

• Design, scale, and launch manufacturing equipment for new products being produced for the first time, including the development of automation system architecture and standards for deployment across multiple production lines
• Produce electrical one-line diagrams and schematics for automated manufacturing equipment; support integration with the factory’s Manufacturing Execution System (MES) and set up equipment reporting to track Overall Equipment Effectiveness (OEE) and other critical machine data
• Collaborate with stakeholders to develop and improve both existing and new testing processes; work across technical teams to understand product integration within pulsed power circuits to optimize test processes aligned with Helion’s top-level generator goals
• Collaborate with machine suppliers on high-level equipment design and functionality; support design reviews, acceptance testing, and equipment buyoff to ensure seamless integration into manufacturing operations
• Implement safety systems that comply with ANSI, ISO, and OSHA standards for high-volume manufacturing equipment to ensure operational safety and regulatory adherence
• Troubleshoot down equipment, identify root causes, and implement long-term solutions to prevent recurrence and ensure sustained manufacturing uptime and efficiency

Required Skills

• Bachelor’s degree in engineering with a minimum of 5 years of experience working with manufacturing controls in high-volume manufacturing environments
• Proficient in electrical schematic design and PLC programming using ladder logic, function block, or structured text (e.g., Allen-Bradley, Siemens)
• Experienced in programming industrial robots, including systems such as Fanuc and Kuka
• Skilled in designing safety systems for automated machines, with relevant experience or qualifications in safety compliance and risk mitigation
• Ability to apply physics-based first principles to challenge design requirements and underlying assumptions, driving better engineering outcomes
• Strong communication skills with proven success influencing cross-functional partners and building effective partnerships with supply chain and production teams

Benefits

• Medical, Dental, and Vision plans for employees and their families
• 31 Days of PTO (21 vacation days and 10 sick days)
• 10 Paid holidays, plus company-wide winter break
• Up to 5% employer 401(k) match
• Short term disability, long term disability, and life insurance
• Paid parental leave and support (up to 16 weeks)
• Annual wellness stipend

Helion is an equal opportunity employer and value diversity at our company. We do not discriminate based on race, religion, color, national origin, gender, sexual orientation, age, marital status, veteran status, or disability status. If you need assistance or an accommodation during the interview process, please let us know.

Compensation Range: $164K - $200K