Senior Metrology Engineer

Pacific Fusion Corporation; San Leandro (CA); On-site; USD 176,000 - 264,000; Full time

Benefits offered by this job

Equity plan

6% employer 401k matching

Paid time off

Medical, Dental, Vision insurance

Job summary

Pacific Fusion Corporation seeks a Senior Metrology Engineer to lead dimensional integrity and quality for precision components in our pulsed power fusion system. You will develop metrology processes and data-driven feedback loops essential for achieving micron-level tolerances in fusion targets.

You will craft in-process inspection procedures, fixtures, and measurement workflows, collaborating across engineering and manufacturing teams to scale from prototyping to high-throughput production.

Qualifications

• Bachelor’s degree in Mechanical or Manufacturing Engineering (or related field).
• Expert-level knowledge of metrology and precision manufacturing; GD&T and engineering drawings mastery.
• Ability to plan integration of inspection systems into workflows.
• Strong analytical skills with data-driven process improvement for fabrication yields.
• Effective communication and collaboration with scientists, engineers, technicians.
• Proficiency in CAD modeling for measurement setups and fixtures.

Responsibilities

• Develop and establish in-process inspection procedures across fabrication stages.
• Coordinate across technical groups to capture production and quality requirements for targets and sub-assemblies.
• Design and fabricate specialized inspection fixtures for high-precision measurement and handling.
• Perform measurement analysis of components using diamond turning, plating, and thin-film processes.
• Establish metrology capabilities and data workflows for prototyping to production scale.
• Select and qualify metrology equipment based on target requirements, cost, schedule, and precision.

Skills

Metrology

GD&T

Engineering drawings

CAD modeling

Data analysis

Communication

Education

B.S. Mechanical/Manufacturing Eng

Master’s or PhD (advantage)

Tools

CAD software

Diamond turning

Non-contact metrology

Radiography

Tomography

Job description

Pacific Fusion was founded in 2023 with the mission to power the world with abundant, affordable, clean energy.

We are rapidly designing and building a pulser-driven inertial fusion system to achieve net facility gain (more fusion energy output than stored energy input). In parallel, we are developing the key components required to build affordable fusion systems.

Our plans are ambitious. We have raised over $900M so far from incredible investors, resourcing us to deliver on these plans. We are bringing together the best scientists, engineers, and operators from the fusion community, hard tech industry, and other sectors. We are united by a shared sense of urgency to provide clean power for the world, particularly managing climate change while meeting growing global energy demand. You can read more about us in this letter from our founders .

Why This Role Matters

Pacific Fusion is looking for a Senior Metrology Engineer to join our growing target fabrication team. In this role, you will be responsible for dimensional integrity and quality of precision components and assemblies ultimately used in our pulsed power fusion system. You will be responsible for finding creative solutions to inspect a wide variety of complex target designs, ensuring that every component meets micron-level tolerances required for successful fusion experiments. Your expertise in developing and implementing advanced metrology processes is critical to establishing data-driven feedback loops necessary in precision manufacturing on the path to commercial fusion energy.

What You'll Do

• Develop and establish in-process inspection procedures to verify component quality throughout various stages of fabrication.
• Work across different technical groups to understand production and quality requirements for fusion targets and their sub-assemblies.
• Design and fabricate specialized inspection fixtures to support high-precision measurement operations and part handling of components as well as integrated engineering systems.
• Perform detailed measurement analysis of precision components fabricated through techniques such as diamond turning, electroplating, and thin-film coating.
• Establish new metrology capabilities and data management workflows that scale from initial prototyping to a high-throughput production environment.
• Select and qualify metrology equipment based on specific target requirements, evaluating cost, schedule, and precision needs to drive the best path forward.

What You Bring

• Bachelor’s Degree in Mechanical Engineering, Manufacturing Engineering, or a related field; a Master’s Degree or PhD is a plus.
• Expert‑level knowledge of metrology and precision manufacturing techniques, including a strong understanding of GD&T and technical drawings.
• Proven ability to plan the integration of inspection systems into larger engineering and manufacturing workflows.
• Strong analytical skills to work through all stages of development, using data‑driven process engineering to improve fabrication yields.
• Effective communication skills and the ability to collaborate closely with scientists, engineers, and technicians to resolve quality issues.
• Proficiency in CAD modeling for designing measurement setups and precision handling fixtures.

Bonus Points For

• Extensive experience with modern metrology tools including non‑contact optical systems, contact probes, radiography, and tomography.
• Experience inspecting high‑precision, small components at the millimeter scale with micron or sub‑micron tolerances.
• Background in developing automated inspection systems for high‑volume production environments.
• Foundational knowledge of material science including how fabrication and assembly processes impact measurement accuracy.
• Project management experience handling complex manufacturing processes from prototype through production operations.

Pay Range:

$175,900 - $263,800 USD

TOTAL COMPENSATION AND BENEFITS FOR ELIGIBLE EMPLOYEES

Equity plan

6% employer 401k matching

Generous paid time off (including sick leave, vacation, paid family leave)

Medical, Dental, and Vision insurance

Actual base salary offered will be determined by: experience, skills, and work location. This range is for base salary, our total compensation includes equity and benefits. We welcome you to apply even if your expectations are outside our listed range.

EQUAL OPPORTUNTITY

Pacific Fusion is committed to creating a diverse environment and is proud to be an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, gender, gender identity or expression, sexual orientation, national origin, genetics, disability, age, or veteran status.

Pacific Fusion is committed to providing reasonable accommodations for qualified individuals with disabilities in our job application procedures and throughout employment. If you need assistance or any accommodation, please let us know.

U.S. EXPORT CONTROL COMPLIANCE

This position may require access to information or technology that is subject to U.S. export control laws, such as ITAR or EAR. Under these regulations, we are required to ensure that such access is provided only to individuals who are classified as 'U.S. Persons.'This status includes U.S. citizens, U.S. nationals, lawful permanent residents (green card holders), and asylees and refugees with such status granted, not pending.

RECRUITING AGENCIES

Pacific Fusion does not accept unsolicited resumes from recruiters or employment agencies without a fully executed recruitment agreement in place. In the absence of such agreement, Pacific Fusion reserves the right to pursue and hire any candidates without an obligation to pay fees. Agencies are requested not to contact Pacific Fusion hiring managers or employees regarding recruiting services.