Senior Mechanical Engineer, Pulsed Power Systems

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

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