Senior FEA Engineer

Thea Energy Inc.; Kearny (NJ); On-site; USD 130,000 - 160,000; Full time

Benefits offered by this job

Health benefits

Equity stock options

20 days PTO

Job summary

Thea Energy is seeking a Senior Finite Element Analyst to join our fast-growing team and drive advanced thermal, structural, and magnetic analyses for our stellarator systems.

With 8+ years of experience in mechanical engineering, applied mechanics, materials and simulation, you will deliver data-driven insights, justify critical design decisions, and mentor junior analysts while supporting design optimization across multi-domain models.

Qualifications

• 8+ years of Finite Element Analysis experience.

Responsibilities

• Sets strategic FEA methodology across primary stellarator systems and mentors analysts.
• Develops and analyzes complex FE models for system-level designs.
• Performs multi-domain simulations including thermal, mechanical, vibration, and magnetic loads.

Skills

FEA expertise

Scripting skills

Problem solving

First-of-its-kind

Mentoring juniors

Multi-domain simulations

Material modeling

Weld & cryogenic materials

Collaboration & communication

Job description

About Thea Energy:

Thea Energy is leveraging recent breakthroughs in stellarator physics and engineering to create a faster and simpler approach to commercializing fusion energy. The company is reinventing the stellarator using computer-controlled arrays of planar coils thereby replacing the intricate, complex modular magnets required in all other stellarator architectures. Thea Energy is on a mission to create a limitless source of zero emission energy for a sustainable future.

Position Overview:

Thea Energy is seeking a highly motivated and experienced Senior Finite Element Analyst to join our rapidly growing team. In this pivotal role, you'll be instrumental in performing advanced analysis to design, optimize, and verify the thermal, structural, and magnetic requirements of our cutting-edge stellarator systems. If you have at least 8 years of professional experience and a strong background in mechanical engineering, applied mechanics, materials, and simulation, you'll be well-positioned to deliver insightful results, provide data-driven recommendations, and justify critical design decisions.

Key Responsibility Areas:

• Sets strategic FEA methodology and architecture across primary stellarator systems, leads first-of-its-kind problem-solving initiatives, mentors team members, and serves as the primary authority on high-risk engineering decisions.
• Develop and Analyze Complex FE Models: Create and oversee system-level architectural models and highly coupled multi-physics simulations to support the design of major stellarator systems and prototyping activities.
• Perform Multi-Domain Simulations: Be responsible for multi-domain models, including thermal, mechanical, vibration, and magnetic loads.

Ideal Experience & Skillsets:

• Extensive FEA Experience: 8+ years of experience performing Finite Element Analysis with commercial software. Experience in scripting and building tools around commercial FEA tools
• Complex Problem Solving: Demonstrated ability to solve complex engineering problems and identify root causes through meticulous analysis.
• First-of-its-Kind Development: Proven experience developing first-of-its-kind components or systems.
• Provides technical guidance and peer-review for junior analysts (Eng I/II/III) to ensure model accuracy and best practices.
• Conduct In-Depth Performance Evaluation: Execute steady-state and transient analyses with accurate material models to evaluate designs for stress/strain, fatigue, and creep during start-up, steady-state operation, shutdown, and off-nominal operating conditions.
• Optimize Structural Designs: Utilize various techniques to optimize structures for optimal performance under all loading conditions, minimizing weight, and maximizing maintainability.
• Drive Design Improvements: Actively participate in the design process, identifying opportunities for improvements that lead to higher-performing, lower-cost, and more maintainable systems.
• Material Modeling: Develop material models and identify required property development to ensure accurate analysis.
• Specialized Materials Knowledge: Serves as the internal Subject Matter Expert (SME) on complex weld evaluations and cryogenic material behavior.
• Adaptability & Drive: Comfortable working to ambitious timelines with an exceptional work ethic, adaptability, and a continuous improvement mindset.
• Collaboration & Communication: A strong team player with excellent communication and collaboration skills.
• Continuous Improvement Mindset: An innate desire to learn, innovate, and critically evaluate ideas, including your own.

Company Benefits

• Salary range $130,000 - $160,000
• Comprehensive health benefits (e.g. medical/dental/vision)
• Employee equity stock options
• 20 days PTO

It's not necessary to meet all of the skillsets outlined above. Please feel free to send us a note and tell us why you would still be a great fit for this role or Thea Energy.

Diversity and Inclusion:

Thea Energy is an equal opportunity employer committed to creating a company of diverse backgrounds. By creating a diverse environment, we will bring new ideas and approaches to solving some of the world’s hardest (and most important) problems. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, gender, sexual orientation, gender identity or expression, national origin, family or marital status, age, disability, veteran's status, or other characteristic protected by applicable laws and regulations.