Senior Materials Diagnostics Engineer

Helion Energy; Everett, Northern (WA, KY); Hybrid; USD 140,000 - 190,000; Full time

Benefits offered by this job

Medical, Dental, and Vision plans

PTO 31 days

Paid holidays

401(k) match

Disability & Life Insurance

Parental leave

Wellness stipend

Job summary

Helion Energy in Everett, WA, is seeking a Senior Materials Engineer to lead materials health monitoring for fusion generators. You will design, qualify, and deploy diagnostics to detect materials degradation under thermomechanical stress, radiation, high electric fields, and coolant environments.

You will collaborate with Materials, Research, and Engineering teams, report to the Lead Materials Scientist, and embed diagnostics into hardware and predictive models for maintenance.

Qualifications

• BS with 10+ years, or MS/PhD with 5+ years in Materials Science, Materials Engineering, Applied Physics, Nuclear Engineering, or related field.
• 5+ years (with PhD or MS) or 10+ years (with BS) of experience in materials diagnostics / NDE / SHM (strain, acoustic, optical, EM, fiberoptic, etc.).
• Familiarity with data analysis / feature extraction for degradation detection (Python preferred).
• Experience designing and executing coupled-stimuli experiments (thermomechanical, electrothermal, irradiation with stress).
• Experience embedding or integrating sensors into structural materials (ceramics, composites, polymers, or metals).

Responsibilities

• Develop and deploy in-situ and ex-situ diagnostics for degradation and failure in fusion-relevant materials and components (e.g., first wall, magnets, insulators, capacitors, HV interfaces, seals).
• Translate failure and degradation modes into measurable signals using sensors, inspection methods, or indirect indicators.
• Design and execute coupled-stimuli experiments and post-irradiation examinations (PIE) to validate diagnostic methods.
• Build test matrices and analysis plans linking microstructural evolution to sensor outputs and component performance.
• Own the materials diagnostics roadmap by converting risk assessments into diagnostic requirements (what to measure, where, how often, and accuracy).
• Collaborate with design engineers to embed diagnostics into hardware and ensure compatibility with system constraints.
• Partner with modeling teams to integrate diagnostic outputs into predictive models and maintenance strategies.
• Productize diagnostic methods and sensors for reliable deployment in fusion environments.
• Document test plans, procedures, and design guidance; communicate results, risks, and recommendations across teams.

Skills

Materials diagnostics

NDE/SHM

Python analytics

Coupled-stimuli tests

Sensors integration

Education

MS/PhD in relevant field

BS in relevant field

Job description

Helion Energy in Everett, WA, is seeking a Senior Materials Engineer to lead materials health monitoring for fusion generators. You will design, qualify, and deploy diagnostics to detect materials degradation under thermomechanical stress, radiation, high electric fields, and coolant environments.

You will collaborate with Materials, Research, and Engineering teams, report to the Lead Materials Scientist, and embed diagnostics into hardware and predictive models for maintenance.