Senior Mechanical Engineer

Realta Fusion; Madison (WI); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Equity stock options

Health, dental, and vision insurance

Retirement savings plan

Flexible PTO

Job summary

Realta Fusion is seeking a Senior Mechanical Engineer to lead design and development of fusion tech tied to Hammir-DD, Realta’s reactor-scale platform, ahead of a pilot plant. You will guide mechanical system design, perform analyses, and collaborate across engineering and scientific teams to advance the technology roadmap.

You will mentor junior engineers, coordinate with vendors, and ensure safety and quality standards are embedded in design and fabrication activities.

Qualifications

• BS in Mechanical Engineering, Nuclear Engineering, or related field, plus 5-8 years’ experience
• Experience with 3D CAD design tools (SolidWorks, NX, Creo) and PDM familiarity
• Strong understanding of mechanism design, structural, heat transfer, and thermal analyses; familiarity with ANSYS/COMSOL
• Experience with installation/commissioning of precision scientific, mechanical, cryogenic, hydraulic, plumbing, and vacuum systems
• Ability to supervise small teams and coordinate with researchers, engineers, machinists, and technicians
• GD&T and P&ID proficiency within ASME standards

Responsibilities

• Develop 3D models and technical drawings for beamline and fusion device elements in ultra-high vacuum environments
• Manage full engineering lifecycle from concept to deployment
• Translate concepts into detailed drawings; perform analysis and develop solutions
• Lead mechanical system design, stress analysis, thermal analysis, and fatigue analysis
• Conduct design reviews and generate technical documentation
• Collaborate with vendors and internal resources to fabricate, assemble, test, and validate components
• Provide hands-on support in fabrication and assembly of prototype systems
• Communicate results to project teams and leadership; support programmatic needs
• Contribute to safety standards and implement them within R&D and Engineering
• Foster an inclusive, innovative culture aligned with company values

Skills

3D CAD design

FEM/FEA analysis

Technical leadership

Mech design for vacuum/cryogenics

Education

BS in Mechanical/Nuclear Engineering

MS in Mechanical Engineering (preferred)

Tools

SolidWorks

NX

Creo

PDM

Job description

Lead the design and development of groundbreaking fusion technologies that will help power the future of clean energy.

The Senior Mechanical Engineer will work closely with Realta’s engineering and scientific teams to provide technical leadership, engineering expertise, and critical design input that advances Realta’s technology development roadmap. This individual will play a key role in the design, development, and execution of Hammir-DD, Realta’s reactor‑scale tandem magnetic mirror and development platform ahead of Realta's first‑of‑a‑kind fusion pilot plant. They will be expected to drive complex engineering initiatives, mentor junior engineers, and contribute to strategic decisions that support the commercialization of fusion energy.

Realta Fusion is a rapidly growing start‑up developing compact magnetic mirror fusion energy systems to address the biggest challenge of our time –tackling global climate change while ensuring a sufficient energy supply for at least ten billion people on (and off) earth. We are building a team with diverse talents dedicated to making fusion energy a real solution to humanity’s most pressing problem.

Responsibilities

• Develop 3D models and technical drawings for complex beamline and fusion device elements to be operated in ultra‑high vacuum environments.
• Manage the full engineering lifecycle from conception, construction, and field installation to operational deployment and beyond.
• Translate concepts into detailed engineering drawings, carry out design analysis, identify potential problems, and independent or collaboratively develop solutions.
• Lead efforts involving general mechanical‑system design, mechanical stress analysis, thermal analysis, and fatigue analysis.
• Conduct formal design reviews, generate technical documentation, and respond to questions concerning engineering design and operation.
• Work with vendors and internal resources to fabricate, assemble, test, and validate components and systems.
• Supply hands‑on support in fabrication and assembly of prototype and laboratory systems, up to and including operating machine shop equipment.
• Communication: Synthesize and present technical work internally and externally, communicate daily with project teams and leadership to support programmatic needs.
• Safety: Contribute to the establishment of company safety standards and lead implementation of these standards within R&D and Engineering team.
• Culture and Values: Foster a positive and inclusive work environment that aligns with the company's mission, values, and sustainability goals, promoting innovation, collaboration, and employee engagement

Required Qualifications

• Education: BS in Mechanical Engineering, Nuclear Engineering, or a related field, plus 5-8 years’ work experience
• Extensive experience and expertise in 3D CAD design with current CAD software tools (SolidWorks, NX, Creo, etc.) and familiar with PDM
• Demonstrated understanding of mechanism design, structural analysis, heat transfer, and thermal analysis, and the ability to leverage FEA tools such as ANSYS or COMSOL to solve engineering problems
• Technical experience with the installation and commissioning of precision scientific, mechanical, cryogenic, hydraulic, plumbing, and/or vacuum systems
• Substantial technical experience with advanced knowledge and judgement in most of the following areas:
  • Design, commissioning, and operation of ultra‑high vacuum systems and parts compatible with vacuum environments
  • Welding, machining, and mechanical assembly processes and techniques
  • Project management abilities defined as the ability to control scope, cost, and schedule
  • Metrology, inspection, quality control, and test methods related to manufacturing using CMMs, laser trackers, FARO arms, or other test equipment
• Demonstrated ability to supervise and safely direct activities of small teams of technical personnel
• Ability to interact and communicate efficiently with researchers, engineers, designers, machinists, and technicians to provide a high level of customer service
• GD&T and P&ID proficiency within ASME standards
• Collaboration: Exceptional interpersonal and communication skills (written, verbal, public presentation) to collaborate effectively with colleagues, external partners, and stakeholders

Preference will be given to candidates with:

• Master’s Degree or higher in Mechanical Engineering or related field
• Professional Engineering (PE) license
• Experience in designing for and working within radiation environments
• Experience with cryogenic systems for ultra‑high vacuum applications
• Experience with high‑voltage systems, megawatt‑scale heating and cooling systems, and specialty materials for fusion or particle accelerator applications
• Experience with nuclear Commercial‑Grade Dedication (CGD) or related standards

Compensation and Benefits

What we are working on is hard… and hugely important. Realta Fusion is assembling a talented team bound together by a passion to solve humanity’s biggest challenge with first‑of‑a‑kind technology. Additionally, Realta offers:

• Competitive compensation package, including equity stock options
• Comprehensive benefits including health, dental, and vision insurance, plus a retirement savings plan
• Flexible paid time off (PTO) to support work‑life balance
• Work and live in Madison, Wisconsin — one of America’s most livable and vibrant cities

We value diversity as a critical factor in innovation and believe a diverse team is necessary to solve the toughest problems. We aim to create an inclusive environment that unleashes the full creativity of our team members from a wide variety of backgrounds and experiences. We provide equal employment opportunities to all individuals based on merit and without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, veteran status, or any other protected status under applicable laws.