Lead Electromechanical Engineer, Reel-to-Reel Web Handling

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

Job summary

Thea Energy in the United States (New Jersey) seeks a Senior Electromechanical Engineer specializing in Web Handling for Reel-to-Reel processes to lead the development of our manufacturing infrastructure. You will architect automated systems that process our superconducting magnets, bridging high-precision mechanical design with advanced control software.

Ideal candidates bring 8+ years of reel-to-reel experience, expertise in Beckhoff/TwinCAT 3, EtherCAT, NX CAD, and in-line inspection methods.

Qualifications

• BS, MS, or PhD in Mechatronics, Mechanical Engineering, Electrical Engineering, or related fields.
• 8+ years of experience in electromechanical design and commissioning of reel-to-reel equipment in delicate material applications.
• Expertise with Beckhoff/TwinCAT 3, EtherCAT, and structured text programming.
• 3D CAD NX and use of FEA or multibody dynamics to validate designs.
• Ability to solve first-of-a-kind engineering challenges where no off-the-shelf solution exists.

Responsibilities

• Design hardware and controls for bespoke reel-to-reel process machines; ensure integration with control software.
• Serve as SME for roll-to-roll tension control, web handling, steering, winding dynamics, and inline modules.
• Scope and design electromechanical equipment for fragile superconducting tape with zero-defect tolerance.
• Manage external vendors and integrators for large-scale equipment; ensure safety and performance.
• Design and implement in-line inspection systems (vision, laser) to capture process data.
• Develop strategies to increase manufacturing throughput and yield through automation.

Skills

Beckhoff/TwinCAT 3

EtherCAT

Structured Text

NX CAD

FEA

Winding Algorithms

Mechatronics

First-of-a-kind Engineering

Education

BS/MS/PhD in Mechatronics/Mechanical/Electrical

Tools

NX

FEA/Multibody Dynamics

Job description

Thea Energy in the United States (New Jersey) seeks a Senior Electromechanical Engineer specializing in Web Handling for Reel-to-Reel processes to lead the development of our manufacturing infrastructure. You will architect automated systems that process our superconducting magnets, bridging high-precision mechanical design with advanced control software.

Ideal candidates bring 8+ years of reel-to-reel experience, expertise in Beckhoff/TwinCAT 3, EtherCAT, NX CAD, and in-line inspection methods.