Senior Mechanical Design Engineer

Inertia; Livermore (KY); On-site; USD 180,000 - 240,000; Full time

Job summary

Inertia in the United States seeks a Senior Mechanical Design Engineer in the laser division to help develop ultra-high energy pulsed laser systems for fusion energy, including solid-state laser hardware, large-aperture opto-mechanical mounts, vacuum chambers, thermal management, and test stands. You will gather requirements, conceptualize architectures, lead small design teams, validate with FEA/CFD, integrate components into large CAD assemblies, and mentor engineers.

U.S.

Qualifications

• 10+ years of mechanical design engineering experience.
• Proven ability to deliver novel and innovative solutions.
• Proficiency with 3D CAD packages (SolidWorks preferred).
• GD&T, drafting, tolerance analysis expertise.
• FEA and CFD experience with empirical validation.
• Manufacturing process knowledge and DFM focus.
• Experience with precision components (linear stages, encoders, etc.).
• Full lifecycle design including procurement, assembly and test.
• Experience with laser/optical instruments and cleanroom envs.
• US citizenship or permanent residency required.

Responsibilities

• Gather and develop requirements for systems with stakeholders across disciplines.
• Conceptualize system architectures based on high-level requirements.
• Lead small design teams for precision mechanical and opto‑mechanical equipment.
• Design mechanical, opto‑mechanical, and electro‑mechanical systems.
• Validate designs with static and modal FEA, hand calculations, etc.
• Present at design reviews to science and management stakeholders.
• Integrate precision hardware into large CAD assemblies with BIM data.
• Specify components, manage data transfer to suppliers, inspect hardware.
• Assemble prototype hardware and execute test plans for validation.
• Provide assembly documentation and installation schedules.
• Guide and mentor other engineers.

Skills

Leadership / mentoring

Requirements gathering

System architecture

DFM (design for manufacturability)

Finite element analysis (FEA)

CFD analysis

Laser/system design experience

High-voltage / high-vacuum experience

Quality / tolerancing (GD&T)

Engineering leadership

Education

Bachelor's degree in Mechanical Engineering

Tools

SolidWorks

CREO

Autodesk Inventor

SolidWorks PDM

Job description

Overview

We are seeking a Senior Mechanical Design Engineer within the laser division, to play a key role in developing the next generation of ultra‑high energy pulsed laser systems for fusion energy. Typical design projects would include the design and development of solid‑state laser hardware and systems, large‑aperture opto‑mechanical mounts and positioning systems, support structures, vacuum chambers and systems, thermal management systems, and test stands and diagnostics.

Primary Responsibilities

• Gather and develop requirements for systems with stakeholders across all disciplines

• Conceptualize system architectures and concepts based on high‑level requirements

• Lead small teams in the design of precision mechanical and opto‑mechanical equipment and systems for IFE facilities

• Design mechanical, opto‑mechanical, and electro‑mechanical equipment and systems

• Validate design work with appropriate analysis (static and modal FEA, hand calculations, etc.)

• Present at design reviews to science and management stakeholders

• Work closely with other disciplines in the design and coordination of activities

• Integrate precision opto‑mechanical, fluidic, and electrical hardware, designed both in‑house and by subcontractors, into large‑scale CAD assemblies that include facility BIM data

• Perform detailed component materials and finish specifications, manage technical data transfer to suppliers, inspect and qualify hardware following procurement

• Assemble prototype hardware; develop and execute test plans for subsystem performance validation

• Utilize large‑scale CAD assemblies to provide assembly documentation and installation schedules for opto‑mechanical and electrical systems

• Guide and mentor other engineers

Required Qualifications

• 10+ years of experience as a mechanical design engineer

• Proven history of delivering novel and innovative solutions to challenging problems

• Proficiency with 3D CAD packages; SolidWorks (preferred), CREO, Autodesk Inventor, etc.

• Thorough knowledge of drafting, tolerance analysis, and Geometric Dimensioning and Tolerancing (GD&T)

• Demonstrated experience with FEA - Structural, Modal, Random Vibration with empirical validation

• Experience with CFD analysis with empirical validation (preferred)

• Practical knowledge of manufacturing processes (machining, sheet metal, welding) and design for manufacturability (DFM)

• Experience specifying components for precision design: linear stages, rotary motors, encoders, optical sensors, pneumatic components, vacuum components, etc.

• Full design lifecycle experience including design, procurement, assembly, and test of mechanical systems

• Experience with cleanroom procedures, high‑voltage, and high‑vacuum environments

• Experience designing laser systems or optical instruments

• Experience with Product Data Management Systems; SolidWorks PDM (preferred)

• Applicants should be able to work both autonomously as well as collaboratively to execute tasks in support of various teams within the company

• Due to the nature of this position, applicants must be U.S. citizens or permanent residents.

Salary & Benefits

• The base salary range for this role is $180,000 - $240,000 per year; The pay range provided is an estimated base range for this role. Exact compensation may vary based on skills, experience, and education.

• We offer market‑competitive compensation and an excellent benefits program, including Medical, Dental, and Vision plans, company‑paid holidays, matching 401k, and more!