R&D Test Engineer

Commonwealth Fusion Systems; United States; On-site; USD 120,000 - 190,000; Full time

Benefits offered by this job

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

Job summary

Commonwealth Fusion Systems is seeking an R&D Test Engineer in the United States to drive testing and risk retirement for HTS magnet systems. You will design, build, and commission test equipment across mechanical, electrical, and process subsystems, partnering with manufacturing, R&D, procurement, and SPARC teams to meet aggressive timelines.

The role requires a strong foundation in mechanical, electrical or related physics disciplines, plus 5+ years delivering reliable data from specialized

Qualifications

• Bachelor's degree in engineering or science field required; mechanical/electrical engineering or applied physics preferred.
• 5+ years designing, building and commissioning specialized test or industrial equipment with proven data delivery.
• 1+ years using CAD software to design electromechanical assemblies.
• Understanding of mechanical loading, failure modes and material strength, including fasteners design.
• Knowledge of tolerancing, GD&T, form/fit/function, material selection, DFM and DFA.
• Solid grasp of electromagnetic fundamentals: voltage, current, resistance, Ohm’s law, AC/DC, solenoids.
• Strong troubleshooting and problem-solving skills with ability to innovate.
• Proven collaboration and active listening to facilitate productive discussions.
• Excellent written and verbal communication; high motivation and quick execution.

Responsibilities

• Own and retire technical risks by designing, procuring, building and commissioning test equipment.
• Develop test plans with instrumentation and controls for repeatable data.
• Prepare Test Readiness Reviews to ensure safety and necessity.
• Design experiments that match fast pace and schedules.
• Troubleshoot integration and test discrepancies during build and operation.
• Iterate on designs to improve test efficiency.
• Create analytical models from first principles to predict results.
• Compile results and communicate technical topics to both technical and non-technical audiences.

Skills

Mechanical design

Electrical systems

Data analysis

Problem solving

Instrumentation

Collaboration

Communication

Education

Bachelor's degree in engineering or science

Tools

CAD software

Job description

Join the power movement as an R&D Test Engineer
The role of the R&D Test Engineer is to seamlessly flex between multiple disciplines and groups to effectively execute tests and projects on aggressive schedules supporting Commonwealth Fusion System’s mission. This engineer will be primarily responsible for testing and retiring risks for CFS’ HTS magnets and in particular, focus on the mechanical, electrical, and process design and construction of the test equipment and supporting subsystems. The ideal candidate will have a fundamental understanding of at least one of the following engineering disciplines: mechanical, electrical, or fluids. They will be responsible for the design, build, and commissioning of equipment in support of development, qualification and production test objectives. They will work collaboratively across manufacturing, R&D, procurement, and SPARC teams to achieve their test campaigns. It is also the role of the R&D Test Engineer to help the combined stakeholders come to a consensus on why a test is required and what data is deemed essential for the outcome to be achieved.

What you'll do:

- Own and retire technical risks by designing, analyzing, procuring, building, and commissioning test equipment utilizing your knowledge of physics, structures, instrumentation and controls, mechanical and electrical systems

- Understand, challenge and maintain well-documented requirements and risks for the system or component under test

- Develop test plans that effectively retire technical risks including defining appropriate instrumentation and controls necessary to obtain repeatable and reliable data
Identify and mitigate safety hazards associated with test equipment and test plans

- Design safety into the system and produce safety documentation such as job hazard assessments

- Prepare and lead Test Readiness Reviews (TRRs) prior to executing testing to ensure all test activities are both required and safe

- Design experiment campaigns that match our fast pace and work hard to maintain the proposed schedule

- Troubleshoot and resolve integration and test discrepancies during build, commissioning and operation

- Iterate on designs, equipment and operations for repeat tests to improve test efficiency

- Create analytical models based on first principles to predict test results

- Compile test results clearly for review and effectively communicate technical topics to both technical and non technical audiences

What we're looking for:

- Bachelor's degree in engineering or science field is required; mechanical engineering, electrical engineering or similar applied physics degree

- 5+ years experience designing/building/commissioning specialized test or industrial equipment with hands on experience and a proven ability to deliver reliable data (A Master’s degree with similar experience may be substituted)

- 1+ years using CAD software to design electromechanical assemblies

- Proven understanding of mechanical loading, failure modes, and material strength including fasteners design and bolted joints

- An understanding of how mechanical engineering fundamentals support complex design maturation including but not limited to tolerancing, GD&T, form/fit/function, material selection, DFM, and DFA

- A solid grasp of electromagnetic fundamentals – voltage, current, resistance, Ohm’s Law, AC/DC, right-hand rule, solenoids, etc.

- Proven troubleshooting/problem-solving skills with an ability to innovate creative solutions to challenging problems

- Proven collaboration skills including active listening and facilitating a productive discourse on problems

- Exceptional communication skills through both written and verbal methods
High self-motivation and drive to execute quickly. A can‑do attitude and an eagerness to learn

Bonus points for:

- Experience with structural FEA software, especially ANSYS and COMSOL, bolt loading calculations, and failure criteria

- Experience using NX and Teamcenter

- Experience with high field magnet testing traditional or superconducting

- Experience with weld design / stress analysis

- Experience with commissioning new test facilities

- Experience with designing fluid systems – P&IDs, component selection, ASME design codes.

- Experience with developing and executing complex test procedures, in particular tests that include multiple skill sets, different testing phases, and 3rd parties

- Familiarity with superconducting magnets (Lorentz loads, magnet design, conductor design)

- Experience with cryogenic equipment design and use for liquid nitrogen and supercritical helium use – vacuum jacketed equipment, cryocoolers, phase separators, cold traps

- Experience with high vacuum equipment design and use – roughing pumps, turbopumps, ion gauges, residual gas analyzers

- Experience with high voltage and high current power equipment design and use – power supplies, water cooled cables, insulation

Must-have requirements:

- Ability to occasionally lift up to 50 lbs

- Perform activities such as stooping, climbing, typing, standing, or sitting for extended periods of time

- Dedication to safety to mitigate industrial hazards that may include heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, and cryogenics

- Ability to work in industrial or loud environments, with proper PPE

- Willingness to travel or work required nights/weekends/on-call occasionally

#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.

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