Electromechanical Engineer

Hitachi, Ltd.; Kearny (NJ); Hybrid; USD 130,000 - 165,000; Full time

Benefits offered by this job

Salary range

Health benefits

Stock options

PTO 20 days

Job summary

Thea Energy in the United States (New Jersey) seeks a Senior Electromechanical Engineer specializing in Web Handling in Reel-to-Reel processes to lead the design of automated manufacturing for our superconducting magnets. You will serve as SME for roll-to-roll tension control, web handling, and winding dynamics, guiding transitions from R&D to production.

You will collaborate with manufacturing and design teams, manage external vendors, and implement inline inspection systems to capture

Qualifications

• 8+ years of electromechanical design and commissioning of reel-to-reel equipment.
• Experience with delicate material applications (e.g., semiconductor, battery electrode).
• Proficiency with Beckhoff/TwinCAT 3, EtherCAT and structured text programming.
• Experience with taper tension and winding algorithms is highly desired.
• Strong 3D CAD skills (NX preferred) and validation via FEA or multibody dynamics.
• Ability to solve first-of-a-kind engineering challenges with no off-the-shelf solution.

Responsibilities

• Design the hardware and controls for bespoke reel to reel process machines, ensuring seamless integration between high-precision mechanical assemblies and complex control software.
• Serve as the Subject Matter Expert (SME) for machine design enabling roll to roll tension control, web handling and steering, winding dynamics, and in-line process modules, providing technical guidance to the manufacturing and design teams.
• Scope and design electromechanical equipment to handle fragile high temperature superconducting tape with zero-defect tolerance.
• Manage external vendors and integrators for the fabrication of large-scale equipment, ensuring adherence to Thea Energy’s rigorous performance and safety standards.
• Design and implement advanced in-line inspection systems (e.g., computer vision, laser interferometry) to capture high-fidelity process data during continuous manufacturing.
• Develop long-term strategies for manufacturing throughput, identifying bottlenecks in the R2R process and implementing automated solutions to increase yield and reliability.

Skills

Beckhoff/TwinCAT 3

EtherCAT

Structured text programming

Taper Tension

Winding algorithms

3D CAD (NX preferred)

FEA / multibody dynamics

First-of-a-kind problem solving

Education

BS/MS/PhD in Mechatronics, Mechanical Engineering, Electrical Engineering, or related fields

Tools

NX CAD

FEA software

Multibody dynamics

Job description

About Thea Energy:

Thea Energy is leveraging recent breakthroughs in stellarator physics and engineering to create a faster and simpler approach to commercializing fusion energy. The company is reinventing the stellarator using computer-controlled arrays of planar coils thereby replacing the intricate, complex modular magnets required in all other stellarator architectures.

Thea Energy is on a mission to create a limitless source of zero emission energy for a sustainable future.

Position Overview:

We are looking for a Senior Electromechanical Engineer specializing in Web Handling in Reel-to-Reel (R2R) processes to lead the development of our core manufacturing infrastructure. This is a high-impact role where you will be responsible for the architectural design of the automated systems that process our proprietary superconducting magnets. You will act as the technical authority for web-handling and tension-control systems, guiding the transition from R&D prototypes to high-reliability industrial production lines.

Key Responsibility Areas

• Design the hardware and controls for bespoke reel to reel process machines, ensuring seamless integration between high-precision mechanical assemblies and complex control software.
• Serve as the Subject Matter Expert (SME) for machine design enabling roll to roll tension control, web handling and steering, winding dynamics, and in-line process modules, providing technical guidance to the manufacturing and design teams.
• Scope and design electromechanical equipment to handle fragile high temperature superconducting tape with zero-defect tolerance.
• Manage external vendors and integrators for the fabrication of large-scale equipment, ensuring adherence to Thea Energy’s rigorous performance and safety standards.
• Design and implement advanced in-line inspection systems (e.g., computer vision, laser interferometry) to capture high-fidelity process data during continuous manufacturing.
• Develop long-term strategies for manufacturing throughput, identifying bottlenecks in the R2R process and implementing automated solutions to increase yield and reliability.

Ideal Experience & Skillsets

• BS, MS, or PhD in Mechatronics, Mechanical Engineering, Electrical Engineering, or related fields.
• 8+ years of experience in the electromechanical design and commissioning of complex reel-to-reel equipment, preferably in delicate material applications (e.g., semiconductor, battery electrode, or specialized aerospace).
• Expertise with Beckhoff/TwinCAT 3, EtherCAT, and structured text programming. Experience with "Taper Tension" and specialized winding algorithms is highly desired.
• Expertise in 3D CAD (NX preferred) and the use of FEA or multibody dynamics simulation to validate machine designs.
• Ability to solve "first-of-a-kind" engineering challenges where no off-the-shelf solution exists.

Company Benefits

• Salary Range $130,000- $165,000
• Comprehensive health benefits (e.g. medical/dental/vision)
• Employee equity stock options
• 20 days PTO

Diversity and Inclusion:

Thea Energy is an equal opportunity employer committed to creating a company of diverse backgrounds. By creating a diverse environment, we will bring new ideas and approaches to solving some of the world’s hardest (and most important) problems. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, gender, sexual orientation, gender identity or expression, national origin, family or marital status, age, disability, veteran’s status, or other characteristic protected by applicable laws and regulations.