Senior Manufacturing Engineer - NPI Fremont, CA

Pacific Fusion Corporation; Fremont (CA); Hybrid; USD 138,000 - 207,000; Full time

Benefits offered by this job

Equity plan

6% employer 401k matching

Paid time off (vacation, sick leave, F

Medical, Dental, Vision insurance

Job summary

Pacific Fusion is pioneering pulser-driven inertial fusion systems in Fremont, CA, and seeks a manufacturing/process engineer to shepherd prototype components into production-ready pulser assemblies.

You will own assembly processes, transition parts from prototyping to high-volume production, and partner with design engineering to improve manufacturability and tooling. Strong hands-on manufacturing experience is essential.

Qualifications

• 3–7 years of manufacturing or process engineering experience on a production floor.
• Demonstrated experience mentoring technicians on a production line.
• Strong understanding of mechanical assembly, work instructions, and production documentation.
• Hands-on experience with complex electromechanical assembly and high-voltage/pulsed power hardware preferred.
• Familiarity with quality management systems and root cause analysis methods.

Responsibilities

• Own end-to-end manufacturing processes for pulser module assembly from work instruction to build acceptance.
• Lead the transition of new components from design/prototyping into full-scale production and NPI.
• Collaborate with technicians to implement fast, effective on-floor solutions to keep builds progressing.
• Manage build schedules using MS Project and communicate status across the team.
• Provide manufacturing feedback to design engineering, drive DFMs, and support first article builds.
• Identify and resolve non-conformances, conduct root-cause analysis, and implement corrective actions.
• Define tooling and fixtures to support safe, repeatable assembly operations.
• Track metrics (cycle time, yield, first pass) and drive improvement initiatives.
• Support scale-up from low-rate production to higher volumes and define completion steps.

Skills

Manufacturing experience

Mentoring technicians

Mechanical assembly

Engineering drawings & GD&T

Quality systems & root cause

CREO

Education

BS in Mechanical Engineering

Tools

CREO

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

This role will drive transitioning prototype components to production-ready pulser systems.

What You'll Do

• Own end-to-end manufacturing processes for pulser moduleassembly, from work instruction development through buildcompletion and acceptance
  
• Manage the transition of new electrical components fromthe design and prototyping phase into full-scale productionand integration for new product introduction
  
• Work alongside the technicians to provide fast solutions thatcan be quickly executed to keep the build progressing
  
• Support documentation handoff to the production team forthe build processes as well as issues and their respectiveresolutions
  
• Manage build schedule using Microsoft project to communicate within the company
  
• Partner with design engineering to provide manufacturingfeedback, drive DFM improvements, and support first articlebuilds
  
• Identify and resolve production non-conformances, leadingroot cause analysis and implementing corrective actions toprevent recurrence
  
• Define and develop tooling, fixtures, and equipmentrequirements to support safe, efficient, and repeatableassembly operations
  
• Track and report production metrics — cycle time, yield, firstpass rate — and drive initiatives to hit and exceed targets
• Support the scale-up of assembly operations as PacificFusion transitions from low-rate initial production to highervolume output
  
• Support schedule management by clearly defining steps tocompletion

What You Bring

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

Bonus Points For

• Experience in aerospace, defense, energy, or other high-complexity hardware industries
  
• Familiarity with Lean manufacturing, Six Sigma, or othercontinuous 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 IndustrialEngineering (or equivalent experience)
• Experience using CREO

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.