Mechanical Engineer, RF Systems

Lever, Inc.; Massachusetts; Hybrid; USD 90,000 - 145,000; Full time

Benefits offered by this job

Equity

13 Company-wide Holidays

Flexible vacation days

10 sick days

Parental leave policy

Health, dental, and vision insurance

401(k) with employer matching

Professional growth opportunities

Team-building activities

Job summary

Commonwealth Fusion Systems in the United States seeks a Mechanical Engineer, RF Systems to own the RF Heating plant infrastructure design, from coax lines to cooling plates, translating requirements into manufacturable hardware.

You will work with RF and electronics engineers, process engineers, and CAD drafters, delivering robust, scalable solutions while ensuring thermal, structural, and manufacturing considerations are integrated from ideation to plant integration.

Qualifications

• Bachelor's degree in Mechanical Engineering, Physics, or related field.
• 5+ years hands-on mechanical design experience in industrial, heavy machinery, high-power electronics, EV, or aerospace environments.
• Demonstrated experience as the primary creator and owner of mechanical design architectures, core design engineer.
• Direct experience performing structural loads and thermal analyses to validate designs.
• High proficiency in 3D CAD software and GD&T-based manufacturing drawings.

Responsibilities

• Design specialized RF Heating plant components with RF Engineers, including coaxial lines and devices like stub tuners and RF testing loads.
• Decompose system requirements into mechanical specifications, owning the mechanical designs for the RF Heating system.
• Collaborate daily with CAD drafting team, provide guidance, reviews, and release drawings.
• Partner cross-functionally with RF engineers, electronics engineers, process engineers, and other disciplines.
• Architect thermal management by integrating water and air cooling loops into high-power electronics enclosures and plant systems.
• Develop large sheet metal components, mounting hardware for PCBs, cold plates, and more.
• Perform structural loads analysis and thermal analyses to ensure design viability.

Skills

Mechanical design

Thermal analysis

Structural analysis

3D CAD (GD&T)

Heat transfer

Education

Bachelor's degree in Mechanical Engineering

Tools

Siemens NX

Teamcenter

Job description

About Commonwealth Fusion Systems:

Commonwealth Fusion Systems is on a mission to deliver the urgent transition to fusion energy.

Combining decades of research, top talent, and new technologies, we’re designing and building commercially viable fusion power plants. And we're working with policymakers, suppliers, and many others to build the energy industry of the future.

We’re in the best position to make it happen. Since 2018, we’ve raised $4 billion of capital, making us the largest and leading fusion company in the world.

Now we’re looking for more thinkers, doers, builders, and makers to join us. People who’ll bring new perspectives, solve tough problems, and thrive as part of a team.

If that’s you and this role fits, we want to hear from you.

Join the power movement as an Mechanical Engineer, RF Systems

SPARC sustains fusion reactions by feeding >25MW of 120MHz RF power into the tokamak to heat the plasma to 100 million Kelvin. We need a Mechanical Engineer to design the critical physical infrastructure that routes this massive power, from coax transmission lines that span the entire plant to the intricate cooling plates required for high-power electronics.

At this level, you will own the physical design and integration of robust mechanical systems, translating requirements into manufacturing‑ready hardware. You will design everything from large‑scale utility interfaces and custom bellows to sheet metal parts and custom heat sinks, taking designs from ideation and CAD modeling through fabrication and direct plant integration.

For more information on the SPARC RF plant, see the SPARC journal papers here:

• Overview of the SPARC tokamak
• Physics basis for the ICRF system of the SPARC tokamak

What you’ll do:

• Design specialized RF Heating plant components working closely with RF Engineers. These include large‑diameter coaxial transmission lines and devices such as stub tuners and RF testing loads
• Decompose high‑level system requirements into actionable mechanical specifications, owning the mechanical designs for the RF Heating system
• Collaborate daily with a dedicated CAD drafting team, providing clear guidance to detail, rigorously reviews, and releases
• Partner cross‑functionally with RF engineers, electronics engineers, process engineers, and other disciplines
• Architect thermal management solutions by integrating complex water and air cooling loops directly into high‑power electronics enclosures and plant systems
• Develop large sheet metal components, precise mounting hardware for custom printed circuit board assemblies, cold plates, and more
• Perform structural loads analysis and thermal analyses to ensure design viability

What we’re looking for:

• Bachelor’s degree in Mechanical Engineering, Physics, or a related field
• 5+ years of hands‑on mechanical design experience in industrial, heavy machinery, high‑power electronics, electric vehicle, or aerospace environments
• Demonstrated experience as the primary creator and owner of mechanical design architectures, operating as a core design engineer
• Direct experience performing structural loads analysis and thermal analyses to validate mechanical designs
• High proficiency in 3D CAD software and creating detailed manufacturing drawings utilizing GD&T standards
• Possess a strong fundamental understanding of heat transfer, structural mechanics, and fluid dynamics

Bonus points for:

• Experience using Siemens NX for 3D modeling and Teamcenter for product lifecycle management and drawing release workflows
• Background decomposing complex system requirements into clear mechanical hardware specifications
• Experience designing large‑scale pipe routing, coaxial transmission lines, flanges, bellows, or active water and air cooling systems
• Experience with complex electronics assemblies and the thermal management of such assemblies
• Deep familiarity with sheet metal fabrication processes, machining capabilities, and communicating directly with contract manufacturers

Must‑have Requirements:

• Ability to lift up to 50lbs
• Perform activities such as stooping, climbing, standing, typing or sitting for extended periods of time
• Willingness to travel or work required nights/weekends/on‑call occasionally
• Work in a facility that contains industrial hazards including heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, high current, pressure systems, and cryogenics

$90,000 - $145,000 a year

Salary range for this full‑time position + equity + benefits

The actual salary will depend on level, location, qualifications, and experience. The range displayed on each job posting reflects new hire salaries for the position across all US locations.

Benefits include:

• Competitive compensation with equity
• 13 Company‑wide Holidays
• Flexible vacation days
• 10 sick days
• Generous parental leave policy
• Health, dental, and vision insurance
• 401(k) with employer matching
• Professional growth opportunities
• Team‑building activities

#LI‑Onsite

At CFS, we excel in fast‑paced environments, driven by our values of integrity, execution, impact, and self‑critique. As we grow, we’re eager to bring on mission‑driven folks who offer diverse perspectives and fresh ways to tackle challenges.

We value diversity deeply and are proud to be an equal opportunity employer by choice. We consider all qualified applicants equally, regardless of race, color, national origin, ancestry, citizenship status, protected veteran status, religion, physical or mental disability, marital status, sex, sexual orientation, gender identity or expression, age, or any other basis protected by law.

This role requires compliance with U.S. laws concerning the export of controlled or protected technologies or information (collectively, “Export Control Laws"). Any offer of employment will be contingent on the need for compliance with such Export Control Laws.