Senior Materials Engineer: Fusion Diagnostics & Sensors

Apply; Everett, Northern (WA, KY); Hybrid; USD 120,000 - 180,000; Full time

Benefits offered by this job

Medical, Dental, and Vision plans

PTO 31 days (vacation + sick)

Holiday break

401(k) match

Disability and life insurance

Parental leave

Wellness stipend

Job summary

Helion in Everett, WA seeks a Senior Materials Engineer to lead diagnostics for fusion materials health monitoring. You will design, qualify, and deploy in-situ and ex-situ methods to detect degradation under thermomechanical, radiation, high electric fields, and coolant environments.

You will work cross-functionally to translate failure modes into measurable signals, embed diagnostics into hardware, and integrate results into predictive models and maintenance strategies.

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 at least one of: 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 (e.g., 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

Education

BS in Materials Science

MS in Materials Science

Tools

PIE (Post-Irradiation Examination)

Job description

Helion in Everett, WA seeks a Senior Materials Engineer to lead diagnostics for fusion materials health monitoring. You will design, qualify, and deploy in-situ and ex-situ methods to detect degradation under thermomechanical, radiation, high electric fields, and coolant environments.

You will work cross-functionally to translate failure modes into measurable signals, embed diagnostics into hardware, and integrate results into predictive models and maintenance strategies.