Electromechanical Engineer

Fusion Energy Base; Kearny (NJ); On-site; USD 130,000 - 165,000; Full time

Job summary

Thea Energy is seeking a Senior Electromechanical Engineer with expertise in web handling for Reel-to-Reel processes. You will lead the architecture of automated systems processing proprietary superconducting magnets, serving as SME for tension control, web handling, and inline modules.

You will guide the transition from R&D prototypes to high-reliability production lines, working with vendors and internal teams to scale manufacturing while ensuring safety and performance standards.

Qualifications

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

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.

Skills

Beckhoff TwinCAT

EtherCAT

Structured Text

3D CAD

FEA

Taper Tension

Winding Dynamics

Education

BS in Mechanical Engineering

MS in Mechatronics

PhD (optional)

Tools

NX CAD

FEA Software

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.

$130,000 - $165,000 a year

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.

We may use artificial intelligence (AI) tools to support parts of the hiring process, such as reviewing applications, analyzing resumes, or assessing responses and identifying potential inconsistencies or verification signals in application materials based on available information. These tools assist our recruitment team but do not replace human judgment. Final hiring decisions are ultimately made by humans. If you would like more information about how your data is processed, please contact us.