Senior Manufacturing Engineer

Pacific Fusion; San Francisco (CA); On-site; USD 124,000 - 207,000; Full time

Benefits offered by this job

Equity

6% employer 401k matching

Paid time off

Health insurance

Job summary

Pacific Fusion in San Francisco, CA is seeking a Sr. Manufacturing Engineer to own end-to-end pulser module assembly on the shop floor.

You’ll drive processes, tooling, and workflows, partnering with design engineering to ensure build quality and rapid issue resolution. This hands-on, high-ownership role sits at the heart of our production operations, with opportunities to scale from pilot to higher-volume output and to mentor technicians while delivering measurable improvements in cycle time,

Qualifications

• 3–7 years of manufacturing or process engineering in a hands-on production environment.
• Demonstrated experience leading or mentoring technicians on a production floor.
• Ability to read, interpret, and create engineering drawings, schematics, and GD&T.
• Hands-on experience with complex electromechanical assembly — high voltage, pulsed power, precision mechanical, or similarly demanding hardware preferred.
• Familiarity with quality management systems, non-conformance processes, and root cause analysis methodologies (8D, 5-Why, Fishbone).
• Comfortable working in an early-stage, fast-moving environment where processes are still being defined.
• Hands on experience working at a startup building the prototype units.
• Familiarity with standard machining processes and capable of running equipment.

Responsibilities

• Own end-to-end manufacturing processes for pulser module assembly, from work instruction development through build completion and acceptance.
• Work alongside the technicians to provide fast solutions that can be quickly executed to keep the build progressing.
• Support documentation handoff to the production team for the build processes as well as issues and their respective resolutions.
• Manage build schedule using microsoft project to communicate within the company.
• Partner with design engineering to provide manufacturing feedback, drive DFM improvements, and support first article builds.
• Identify and resolve production non-conformances, leading root cause analysis and implementing corrective actions to prevent recurrence.
• Define and develop tooling, fixturing, and equipment requirements to support safe, efficient, and repeatable assembly operations.
• Track and report production metrics — cycle time, yield, first pass rate — and drive initiatives to hit and exceed targets.
• Support the scale-up of assembly operations as Pacific Fusion transitions from low-rate initial production to higher volume output.
• Support schedule management by clearly defining steps to completion.

Skills

Manufacturing / process engineering

Leadership / mentoring

Mechanical assembly knowledge

GD&T proficiency

High voltage / pulsed power experience

Quality systems & root cause analysis

Reading engineering drawings

Startup environment experience

Education

BS in Mechanical/Manufacturing/Electrical/Industrial Engineering

Tools

MS Project

Machining equipment

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

As a Sr. Manufacturing Engineer on the Operations team, you'll be on the shop floor every day — owning the processes, tooling, and workflows that bring our core fusion hardware to life. You'll work alongside a small team of technicians, drive continuous improvement across the build line, and work closely with design engineering to make sure our pulser modules are built right, every time.

This is a hands‑on, high‑ownership role at the center of Pacific Fusion's production operations. If you thrive in a fast‑moving environment where the hardware is unlike anything built before, this is your seat.

What You'll Do

• Own end-to-end manufacturing processes for pulser module assembly, from work instruction development through build completion and acceptance
• Work alongside the technicians to provide fast solutions that can be quickly executed to keep the build progressing
• Support documentation handoff to the production team for the build processes as well as issues and their respective resolutions
• Manage build schedule using microsoft project to communicate within the company
• Partner with design engineering to provide manufacturing feedback, drive DFM improvements, and support first article builds
• Identify and resolve production non-conformances, leading root cause analysis and implementing corrective actions to prevent recurrence
• Define and develop tooling, fixturing, and equipment requirements to support safe, efficient, and repeatable assembly operations
• Track and report production metrics — cycle time, yield, first pass rate — and drive initiatives to hit and exceed targets
• Support the scale-up of assembly operations as Pacific Fusion transitions from low-rate initial production to higher volume output
• Support schedule management by clearly defining steps to completion

What You Bring

• 3–7 years of manufacturing or process engineering experience in a hands‑on production environment
• Demonstrated experience leading or mentoring technicians on a production floor
• Strong understanding of mechanical assembly processes, work instruction development, and production documentation
• Hands‑on experience with complex electromechanical assembly — high voltage, pulsed power, precision mechanical, or similarly demanding hardware preferred
• Familiarity with quality management systems, non-conformance processes, and root cause analysis methodologies (8D, 5-Why, Fishbone)
• Ability to read, interpret, and create engineering drawings, schematics, and GD&T
• Comfortable working in an early‑stage, fast‑moving environment where processes are still being defined
• Hands on experience working at a startup building the prototype units
• Familiarity with standard machining processes and capable of running equipment

Bonus Points For

• Experience in aerospace, defense, energy, or other high‑complexity hardware industries
• Familiarity with Lean manufacturing, Six Sigma, or other continuous improvement frameworks
• Experience supporting first‑of‑kind or prototype‑to‑production transitions
• Exposure to high voltage or pulsed power systems
• BS in Mechanical, Manufacturing, Electrical, or Industrial Engineering (or equivalent experience)

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.