Senior Manufacturing Engineer

Fusion Energy Base; Everett (WA); On-site; USD 120,000 - 190,000; Full time

Job summary

Zap Energy is seeking a Senior Manufacturing Engineer to be involved in advancing nuclear power technology through fusion and other applications. The candidate will collaborate with design and technician teams to implement experimental designs into operational platforms.

Responsibilities include planning production builds, authoring work instructions, and managing manufacturing processes. Qualifications include a Bachelor's in a relevant field and over 10 years of experience.

The estimated salary range is $120,000–190,000 annually, and applicants are encouraged regardless of background or identity.

Qualifications

• 10+ years of manufacturing engineering experience.
• Strong understanding of engineering fundamentals for mechanical design and manufacturing.
• Hands-on experience in hardware manufacturing.

Responsibilities

• Plan labor requirements for production builds.
• Manage non-conforming parts/assemblies identified during production builds.
• Author work instructions and procedures for the shop floor.

Skills

Batch manufacturing

Electromechanical assembly processes

Mechanical design

Manufacturing processes

Hardware manufacturing

Education

Bachelor of Science in Mechanical, Electrical, Manufacturing, or Aerospace Engineering

Tools

CAD Software

Manufacturing Execution Systems/Software

Job description

Senior Manufacturing Engineer

Zap Energy is advancing the next generation of nuclear power technology across fusion, fission and hybrid applications. Built on an integrated platform of high‑energy‑density physics and pulsed power, liquid metals and advanced materials, and compact, modular systems, Zap is building the foundational technologies needed to deploy the energy sources of the future.

About the Opportunity

Zap Energy is currently looking for a Manufacturing Engineer with a background in batch manufacturing and electromechanical assembly processes. This role will work closely with our Design Engineering team and Technician workforce to translate first‑of‑a‑kind experimental designs into operational scientific platforms for fusion energy research and development.

Role Responsibilities

• Plan labor requirements for production builds, maintenance, repair and operations.
• Author work instructions and procedures that communicate engineering intent to the shop floor.
• Plan assembly cell layout for production builds.
• Identify tooling requirements for production builds.
• Provide manufacturing review/feedback on assembly drawings.
• Manage non‑conforming parts/assemblies identified during production builds.
• Provide configuration management oversight to the design and build teams.
• Plan and execute build flow for production builds and retrofit efforts.
• Author in‑process and final test protocols for production builds.
• Author travelers.
• Provide supervisory oversight of technician team during builds.
• Plan and release assembly kits for production builds.
• Lead commissioning, maintenance, repair and overhaul efforts that require physical transformation of parts and assemblies.
• Provide project execution leadership to an integrated team during the build, commissioning and overhaul phases.

Qualifications and Skills

• Required:
  • Bachelor of Science in Mechanical, Electrical, Manufacturing, or Aerospace Engineering (other relevant fields may apply) from an accredited university.
  • 10+ years of manufacturing engineering experience.
  • Strong understanding of engineering fundamentals for mechanical design and manufacturing.
  • Experience translating engineering drawings into work instructions, operating procedures for manufacturing.
  • Experience setting up and designing manufacturing processes.
  • Hands‑on experience in hardware manufacturing (castings, forgings, additively manufactured components, welding, machining, electromechanical assembly, cleaning, non‑destructive testing methods, tight tolerance assembly, leak testing, final acceptance testing of integrated hardware, and Manufacturing Execution Systems/Software).
• Preferred:
  • Experience with integration of large assemblies (product BOMs in excess of 2000 parts).
  • Experience managing and resolving non‑conforming parts/assemblies.
  • Proven experience and successful track record of completing manufacturing projects.
  • Strong written, personal, technical, and software skills (CAD, scheduling, issue tracking, Excel, Word, PowerPoint, Outlook, etc.).
  • Ability to communicate clearly and appropriately at all levels of the organization.

Employment may be conditioned upon the ability to obtain export authorization. Estimated salary range: $120,000‑190,000 annually. Candidates may be considered for other positions at Zap Energy and actual salary will be based on relevant education, experience, and other qualifications. Range is published in accordance with Washington Equal Pay and Opportunity Act.

Zap Energy is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws and regulations.