Senior Mechanical Engineer - Pulsed Power

Hardware FYI; Everett (WA); On-site; USD 120,000 - 180,000; Full time

Job summary

Zap Energy is seeking a Senior Mechanical Engineer to join the Fusion Pulsed Power team, contributing to mechanical design of high-voltage pulsed power systems from concept through fabrication. You will work with electrical, plasma, and systems engineers to develop hardware at the edge of what's possible.

You will design subsystems and enclosures, produce complete SolidWorks packages, and mentor junior engineers while collaborating across disciplines to resolve interface challenges and ensure

Qualifications

• Bachelor’s degree in Engineering (required).
• 7+ years of mechanical engineering experience with hands-on track record.
• Strong SolidWorks proficiency in parts, assemblies, drawings, and PDM.
• Practical GD&T knowledge (ASME Y14.5).
• Experience designing for high-voltage environments; pulsed power/energy storage is a bonus.
• Ability to take designs from concept to fabricated hardware quickly.
• Experience with Jira or similar work management systems for tasks and EHS/QMS tickets.
• Material selection decisions, fastener torque specs, and tolerance stack-ups.
• Experience with various manufacturing processes (sheet metal, welding, water jet, CNC, 3D printing).
• Strong technical communication across audiences including engineers, technicians, vendors, and executives.

Responsibilities

• Design pulsed power systems, enclosures, structural components, bus work, pneumatics, and tooling hardware.
• Translate requirements into mechanical hardware meeting functional and safety constraints.
• Produce SolidWorks parts, assemblies, drawings, and GD&T callouts.
• Iterate designs based on redlines and feedback from manufacturing and operations.
• Own material selection, torque specs, and tolerance stack-ups.
• Apply DFM and DFA to enable rapid, in-house builds.
• Present designs concisely for design reviews; mentor junior engineers.
• Provide feedback on other designs and perform release drawing redlines.
• Collaborate across electrical, controls, manufacturing, and systems to resolve interfaces.

Skills

7+ yrs exp

SolidWorks

GD&T

High-voltage design

Mentorship

FEA

Sheet metal

Education

Bachelor’s degree in Engineering

Tools

PDM

Jira

FEA tools

Job description

About Zap Energy

Zap is advancing the next generation of nuclear power technology across fusion, fission and hybrid applications. Built on an integrated platform of high-energy-density physics and pulsed power, liquid metals and advanced materials, and compact, modular systems, Zap is building the foundational technologies needed to deploy the energy sources of the future.

About the Opportunity

As a Senior Mechanical Engineer on our Fusion Pulsed Power team, you'll contribute to the mechanical design of high-voltage pulsed power systems from concept through fabrication and integration. You'll work closely with electrical, plasma, and systems engineers to develop hardware that operates at the edge of what's physically possible.

Role Responsibilities

• Design pulsed power systems, subassemblies, enclosures, structural components, electrical bus work, pneumatics, and tooling and integration hardware

• Translate design requirements into mechanical hardware that meets functional, spatial, safety, and operational constraints

• Produce complete SolidWorks part, assembly, and drawing packages with detailed instructions and GD&T callouts appropriate to function and manufacturability

• Iterate and update designs based on redlines and feedback from manufacturing and operations

• Own design decisions around material selection, fastener torque specifications, and tolerance stack-ups

• Apply DFM and DFA methodologies to meet schedules and enable rapid, in-house builds

• Compile information on and present your designs concisely for design reviews

• Provide substantive technical feedback on other engineers' designs, both within and outside the Pulsed Power team

• Perform formal drawing review redlines as part of the release process

• Collaborate across electrical, controls, manufacturing, and systems engineering disciplines to resolve interface and integration challenges

• Provide mentorship to junior level engineers on the team

Qualifications and Skills

• Bachelor’s degree in an Engineering field required

• 7+ years of mechanical engineering experience with a strong hands-on track record

• Strong SolidWorks proficiency in parts, assemblies, drawings, and PDM

• Practical working knowledge of GD&T (ASME Y14.5)

• Experience designing for high-voltage environments; pulsed power, or energy storage is a strong bonus

• Demonstrated ability to take designs from concept to fabricated hardware quickly

• Experience collaborating through a work management system, such as Jira, to manage tasks including Engineering Change Requests and Quality Management System tickets

• Confidence in making engineering decisions around materials, fastening, and structural adequacy

• Experience with configuration management

• Ability to perform first-order structural and mechanical load analyses; FEA experience is a bonus

• Familiarity with designing for a variety of manufacturing processes including sheet metal work, welding, water jet cutting, CNC machining, 3D printing, and other standard machine shop equipment

• Demonstrated technical communication skills for a variety of audiences including other mechanical engineers, engineers and scientists of other disciplines, technicians, project managers, vendors, and executives

Employment may be conditioned upon the ability to obtain export authorization.

Estimated salary range: $120,000-180,000 annually. Candidates may be considered for other positions at Zap Energy and actual salary will be based on relevant education, experience, and other qualifications. Range is published in accordance with Washington Equal Pay and Opportunity Act.

Zap Energy is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws and regulations.