Senior Mechanical Engineer

Lever, Inc.; Kearny, Northern (NJ, KY); Hybrid; USD 110,000 - 180,000; Full time

Job summary

Thea Energy is seeking experienced mechanical engineers to own the design and development of fusion system components. You will lead mechanical design, oversee prototyping, and drive manufacturing integration across subsystems.

Candidates should have 5+ years of experience, a strong background in CAD (SolidWorks/CATIA/NX), and a track record of leading complex assemblies. This role requires proactive collaboration and the ability to meet aggressive deadlines.

Qualifications

• Bachelor’s degree required in a relevant field.
• Minimum of 5 years experience in mechanical engineering roles.
• Experience leading design, build, and commissioning of custom systems.

Responsibilities

• Own design and development of primary and secondary mechanical fusion components and subsystems.
• Collaborate with core system teams to define prototyping requirements.
• Produce engineering drawings and specifications with manufacturing tolerances.
• Design tooling for assembly and qualification testing.
• Perform thermal, structural, and electromagnetic analysis with industry tools.
• Mentor junior engineers and guide problem decomposition.
• Communicate progress and results to stakeholders.

Skills

Mechanical design

Lead design

Thermal analysis

Structural analysis

GD&T

Mentor juniors

Engineering communication

Education

Bachelor’s degree in mechanical engineering, aerospace engineering, physics, or related fields

Tools

SolidWorks

CATIA

NX

Job description

About Thea Energy:

Thea Energy is leveraging recent breakthroughs in stellarator physics and engineering to create a faster and simpler approach to commercializing fusion energy. The company is reinventing the stellarator using computer-controlled arrays of planar coils thereby replacing the intricate, complex modular magnets required in all other stellarator architectures. Thea Energy is on a mission to create a limitless source of zero emission energy for a sustainable future.

Position Overview:

Thea Energy is looking for experienced, highly motivated mechanical engineers to join its rapidly growing team. Mechanical engineers will have ownership of the mechanical design and development of primary and secondary components and subsystems in the development of Thea Energy’s stellarator fusion systems. You will be responsible for structural and thermo-mechanical design, manufacturability, development, and commissioning of these systems. The Thea Energy team is comprised of driven, creative, and fun individuals passionate about solving complex problems.

Key Responsibility Areas:

• Have ownership of the design and development of primary and secondary mechanical fusion components and subsystems
• Work with core system-level development teams to define prototyping requirements
• Produce mechanical engineering designs, drawings, specifications, and parameters from first principles with appropriate tolerances for vendor quoting and manufacturing
• Design tooling for assembly
• Perform thermal, structural, and electromagnetic analysis and simulation using Ansys and COMSOL
• Incorporate design for manufacturing principles and support first builds
• Support the implementation of tooling and manufacturing
• Design and execute qualification testing
• Track and report results and progress against program goals and milestones
• Communicate and collaborate with internal and external stakeholders
• Mentor junior engineers

Ideal Experience & Skillsets:

• Minimum of a bachelor’s degree in mechanical engineering, aerospace engineering, physics, or related fields
• Minimum of 5 years of experience
• Extensive experience as a lead designing, building, and commissioning custom systems
• Experience in mechanical engineering using CAD software (e.g. Solidworks, CATIA, NX, etc.)
• Management of complex assemblies with multiple contributors
• Experience specifying machining, welding, and/or fabrication requirements
• Ability to mentor junior engineers in methods to decompose complex problems, and review that work
• Ability to take initiative and guide the design and analysis of complex components and systems with the aid of peers and team membersAbility to execute and flourish in a fast-paced, rapidly changing environment
• Familiarity with GD&T (ASME Y14.5) & Drawing Standards
• Experience owning systems or complex sub-systems
• Comfortable working to aggressive deadlines
• Exceptional work ethic
• Strong team member with clear communication and collaboration skills
• Innate desire to learn, innovate, and critique ideas including one’s 

$110,000 - $180,000 a year

It’s not necessary to meet all of the skillsets outlined above. Please feel free to send 

Diversity and Inclusion:

Thea