Senior Mechanical Engineer - Fusion Hardware Lead

Pacific Fusion; San Leandro (CA); On-site; USD 138,000 - 264,000; Full time

Benefits offered by this job

Equity plan 6% employer

401k matching

Medical, Dental, and Vision insurance

Generous paid time off

Job summary

Pacific Fusion seeks a Senior Mechanical Engineer to lead mechanical design, structural analysis, and integration for a fusion demonstration system. Own hardware from concept to final assembly, collaborating with physics, systems engineering, and manufacturing teams to meet high-precision requirements.

The role requires 5+ years of hands-on experience, advanced CAD/FEA skills, and strong knowledge of GD&T, manufacturing methods, and risk mitigation.

Qualifications

• Bachelor's in Mechanical Engineering required; Master's or PhD is a plus.
• 5+ years of hands-on mechanical design and structural/thermal analysis for complex hardware systems.
• Advanced proficiency in 3D CAD modeling software (Creo, SolidWorks).
• Extensive experience with Finite Element Analysis software (ANSYS, Abaqus, Creo Simulate) for stress, fatigue, thermal and structural integrity.

Responsibilities

• Lead end-to-end mechanical design, 3D CAD modeling, and detail engineering of complex high-performance components.
• Perform hand calculations, first-principles design, and advanced finite element analysis.
• Translate physics requirements and constraints into robust models and hardware specs.
• Conduct tolerance stack-up analyses to meet strict design interfaces.
• Apply DFM and DFA to optimize performance, weight, cost, and lead times.
• Interface with cross-functional teams to resolve design trade-offs and mitigate risk.
• Prepare and maintain engineering documentation, including GD&T drawings and design review packages.

Skills

Leadership

Finite Element Analysis

Thermal analysis

GD&T knowledge

Problem solving

Communication

Education

Bachelor's in Mechanical Engineering

Master's or PhD a plus

Tools

Creo/SolidWorks

ANSYS/Abaqus/Creo Simulate

GD&T (ASME Y14.5)

Job description

Pacific Fusion seeks a Senior Mechanical Engineer to lead mechanical design, structural analysis, and integration for a fusion demonstration system. Own hardware from concept to final assembly, collaborating with physics, systems engineering, and manufacturing teams to meet high-precision requirements.

The role requires 5+ years of hands-on experience, advanced CAD/FEA skills, and strong knowledge of GD&T, manufacturing methods, and risk mitigation.