Mechanical Design Engineer

Pacific Fusion; San Jose (CA); On-site; 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 is designing and building a pulser-driven inertial fusion system to achieve net facility gain. This role focuses on sealing strategies and large-scale vacuum components, working with internal teams and external partners.

You will mentor junior engineers, document processes, and collaborate with vendors to advance high-vacuum design and integration across systems. Equity and competitive benefits are offered.

Qualifications

• Bachelor's or Master's in Mechanical or Aerospace engineering.
• 5+ years of mechanical design experience with vacuum seals.
• Proficient CAD, FEM and engineering analysis tools.
• Experience with tolerance analysis and FMEA.

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 system integration.
• 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

Mechanical design

FMEA

Tolerance analysis

Mentorship

Education

Bachelor's or Master's in Mechanical/Aerospace engineering

Tools

CREO

CAD

FEM software

Job description

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, andimplementing new solutions to pulser systems.

What You'll Do

• Design and analyze large, high-performance vacuum sealsfor water-to-air, air-to-high-vacuum, and water-to-high-vacuum transitions
• Lead experimental design and testing in collaboration withinternal 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 ensureseal reliability and system safety
  
• Design test assemblies and risk-reduction
  
• Review and present technical work across multidisciplinaryteams; contribute to system-level integration discussions
  
• Provide subject-matter expertise in sealing strategies andhelp guide the integration of systems in the target area
  
• Document sealing processes, validation data, and lessonslearned
  
• Mentor and support junior engineers on design andintegration challenges
  
• Interact with suppliers of vacuum systems components andelectrical testing components for purchasing

What You Bring

Bachelor's or Master's degree in Mechanical, Aerospace, ora 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 AND BENEFITS FOR ELIGIBLE EMPLOYEES

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. We welcome you to apply even if your expectations are outside our listed range.

EQUAL OPPORTUNTITY

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.

U.S. EXPORT CONTROL COMPLIANCE

This position may require access to information or technology that is subject to U.S. export control laws, such as ITAR or EAR. Under these regulations, we are required to ensure that such access is provided only to individuals who are classified as 'U.S. Persons.'This status includes U.S. citizens, U.S. nationals, lawful permanent residents (green card holders), and asylees and refugees with such status granted, not pending.