Mechanical Design Engineer

Uncover; Fremont (CA); Hybrid; USD 138,000 - 207,000; Full time

Benefits offered by this job

Equity plan 6% employer 401k matching

Generous paid time off

Medical, Dental, and Vision insurance

Job summary

Pacific Fusion seeks an experienced mechanical design engineer to advance vacuum seal solutions for high- and ultra-high vacuum systems. You will design, analyze, and test seals, mentor juniors, and collaborate with vendors and partners to ensure safe, robust integration.

Key qualifications include 5+ years in vacuum-seal design, proficiency in CAD/FEM, and strong tolerance/FMEA skills. Attractive compensation includes equity and comprehensive benefits for a mission-driven team.

Qualifications

• Bachelor's or Master's in Mechanical/Aerospace or related field.
• 5+ years in mechanical design with a focus on vacuum seals in high to ultra-high vacuum environments.
• Proficiency in CAD, FEM and engineering analysis tools.
• Expertise in tolerance analysis, FMEA, seal design, and mechanical integration.

Responsibilities

• Design and analyze large, high-performance vacuum seals for water-to-air, air-to-high-vacuum, and water-to-high-vacuum transitions.
• Lead experimental design and testing with internal teams, external vendors, and academic partners.
• Conduct research into novel sealing techniques; define, execute, and evaluate test campaigns.
• Perform FMEA and tolerance stack-up analyses to ensure seal reliability and system safety.
• Design test assemblies and risk-reduction.
• Review and present technical work across multidisciplinary teams; contribute to system-level integration discussions.
• Provide subject-matter expertise in sealing strategies and help guide integration of systems.
• Document sealing processes, validation data, and lessons learned.
• Mentor and support junior engineers on design and integration challenges.
• Interact with suppliers of vacuum systems components and electrical testing components for purchasing.

Skills

Vacuum seals design

CAD

FEM

Tolerance analysis

FMEA

Mechanical integration

Education

Bachelor's or Master's in Mechanical/Aerospace

Tools

CREO

Job description

About Pacific Fusion

Pacific Fusion was founded in 2023 with the mission to power the world with abundant, affordable, clean energy. We are rapidly designing and building a pulser-driven inertial fusion system to achieve net facility gain (more fusion energy output than stored energy input). In parallel, we are developing the key components required to build affordable fusion systems. Our plans are ambitious. We have raised over $900M so far from incredible investors, resourcing us to deliver on these plans. We are bringing together the best scientists, engineers, and operators from the fusion community, hard tech industry, and other sectors. We are united by a shared sense of urgency to provide clean power for the world, particularly managing climate change while meeting growing global energy demand. You can read more about us in this letter from our founders.

Why This Role Matters

This role is critical to the design of systems and components, prototyping, and implementing new solutions to pulser systems.

What You'll Do

• Design and analyze large, high-performance vacuum seals for water-to-air, air-to-high-vacuum, and water-to-high-vacuum transitions
• Lead experimental design and testing in collaboration with internal teams, external vendors, and academic partners
• Conduct research into novel sealing techniques; define, execute, and evaluate test campaigns
• Perform FMEA and tolerance stack-up analyses to ensure seal reliability and system safety
• Design test assemblies and risk-reduction
• Review and present technical work across multidisciplinary teams; contribute to system-level integration discussions
• Provide subject-matter expertise in sealing strategies and help guide the integration of systems in the target area
• Document sealing processes, validation data, and lessons learned
• Mentor and support junior engineers on design and integration challenges
• Interact with suppliers of vacuum systems components and electrical testing components for purchasing

What You Bring

• Bachelor's or Master's degree in Mechanical, Aerospace, or a related engineering field, or equivalent experience
• 5+ years of mechanical design experience with a focus on vacuum seals and systems, including rough, high, and ultra-high vacuum environments
• Strong proficiency in CAD, FEM, and engineering analysis tools
• Proven expertise in tolerance analysis, FMEA, seal design, and mechanical integration

Bonus Points

• For Experience in high vacuum systems design and assembly
• Experience using CREO
• Experience of high voltage electrical work
• Experience implementing instruments controls and software

Pay Range: $138,100 — $207,100 USD

Total Compensation & Benefits for Eligible Employees

• Industry-competitive salary
• Equity plan 6% employer 401k matching
• Generous paid time off (including sick leave, vacation, paid family leave)
• Medical, Dental, and Vision insurance

Actual base salary offered will be determined by: experience, skills, and work location. This range is for base salary, our total compensation includes equity and benefits.

Pacific Fusion is committed to creating a diverse environment and is proud to be an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, gender, gender identity or expression, sexual orientation, national origin, genetics, disability, age, or veteran status.

Pacific Fusion is committed to providing reasonable accommodations for qualified individuals with disabilities in our job application procedures and throughout employment.

If you need assistance or any accommodation, please let us know.

Pacific Fusion does not accept unsolicited resumes from recruiters or employment agencies without a fully executed recruitment agreement in place. In the absence of such agreement, Pacific Fusion reserves the right to pursue and hire any candidates without an obligation to pay fees. Agencies are requested not to contact Pacific Fusion hiring managers or employees regarding recruiting services.