Senior R&D Engineer

Commonwealth Fusion Systems; United States; Hybrid; USD 120,000 - 170,000; Full time

Benefits offered by this job

Competitive salary

Hybrid work environment

Comprehensive benefits

Job summary

Commonwealth Fusion Systems is seeking a Senior R&D Engineer to lead HTS magnet R&D efforts for the NINT program. You will design and test magnet subsystems, develop and deploy test campaigns, and work across mechanical, electrical, materials, fluids, and systems engineering disciplines.

You will drive analyses, build test equipment, and collaborate with I&C teams to capture critical data and ensure successful SPARC NINT coil readiness. Strong leadership and communication are essential.

Qualifications

• Bachelor’s degree in engineering or science field is required.
• 7+ years’ experience as an R&D or test engineer in complex electromechanical systems.
• Experience leading multidisciplinary engineering projects or technical teams.
• Strong knowledge of static structures and heat transfer.

Responsibilities

• Develop new HTS magnet designs and subsystems; design and build R&D test samples and their manufacturing processes.
• Design, build, and commission test equipment to meet R&D objectives.
• Perform structural, electrical, and thermal analyses to support sample design and predict test results.
• Build expertise in HTS magnets, power delivery, cryogenic cooling, and related subsystems.
• Support production, integration, and commissioning of SPARC NINT coils; resolve HTS magnet build/test issues.
• Maintain documented requirements and risks; align stakeholders on necessary data for success.
• Collaborate with I&C engineers to develop instrumentation and data acquisition systems.
• Maintain documentation, schedules, and budgets for test campaigns; develop tools to analyze data.
• Prepare and deliver presentations with trade studies, design reviews, and data reviews to engineers and physicists.

Skills

Multidisciplinary engineering

Mechanical fundamentals

Electrical fundamentals

Materials & fluids

Systems engineering

Data analysis

Education

Bachelor’s degree in engineering or science

Tools

Siemens NX

CAD software

Data acquisition systems

Job description

Join the power movement as a Senior R&D Engineer The NINT Magnet R&D team is responsible for testing and retiring risks for CFS's NINT (non-insulated-non-twisted) HTS magnets. This includes executing development test campaigns for CFS's next-generation NINT magnet technology, and leading RCCA efforts through analysis and testing to resolve issues that may arise with the SPARC NINT magnets currently in production, tokamak integration, and commissioning. HTS magnet technology is inherently multidisciplinary, and a successful Senior R&D engineer will seamlessly flex between disciplines and groups to effectively lead the execution of tests and projects on aggressive schedules supporting CFS's mission. The Senior R&D engineer must have a fundamental understanding of mechanical, electrical, materials, fluids, and systems engineering, or some combination thereof. It is also the role of the R&D engineer to constantly push and challenge the requirements, risks, and test objectives that they are given to help the combined stakeholders come to a consensus on why the planned test is required and what data is deemed essential for the outcome to be achieved.

What you'll do:

• Develop new HTS magnet designs and their associated subsystems, which includes the designing and building R&D test samples, and developing their manufacturing processes and test operations
• Design, build, and commission test equipment required to accomplish R&D test campaign objectives
• Perform structural, electrical, and/or thermal analyses in support of R&D sample design and to predict test results
• Build expertise in testing HTS magnets as well as how to design and build R&D HTS magnets and their associated subsystems, including power delivery, cryogenic cooling, and structures
• Support the production, integration, and commissioning of SPARC NINT coils as issues requiring HTS magnet build and test expertise arise
• Understand, challenge, and maintain well documented requirements and risks for the system or component under test, and align stakeholders on why the planned test is required and what data is deemed essential for the desired outcome to be achieved
• Collaborate with I&C engineers to develop necessary instrumentation and data acquisition systems
• Maintain documentation, schedules, and budgets for test campaigns. Documentation includes: design reviews, wiring lists, P&IDs, schematics, CAD assemblies, drawings, BOMs, data acquisition systems, and operations software
• Develop custom tools to analyze generated data. Compile test results in presentations for review
• Prepare and deliver presentations containing trade studies, design reviews, test readiness reviews, and test data reviews to teams of engineers and physicists

What we’re looking for:

• Bachelor’s degree in engineering or science field is required; mechanical engineering, electrical engineering or similar, or applied physics degree preferred
• 7+ years’ experience as an R&D engineer or test engineer designing, building, commissioning complex electromechanical systems
• Experience working on a multi-disciplinary engineering project, ideally as a technical leader
• Excellent fundamental knowledge of mechanical systems such as static structures and heat transfer
• Experience with selecting and utilizing instrumentation and control components such as thermocouples, voltage and current sensors, oscilloscopes, pressure transducers, strain gauges, heaters, flow meters, fittings and valves
• Experience with developing and executing test procedures
• Proficiency with CAD design in Siemens NX or equivalent CAD software
• Familiarity with electromagnetic fundamentals - voltage, current, resistance, Ohm’s law, AC/DC, right-hand rule, solenoids, etc
• Excellent troubleshooting / problem-solving skills with great attention to detail
• Experience developing and effectively presenting comprehensive trade studies comparing the pros & cons of various technical approaches
• Data reduction and analysis skills that can be used in generating anticipated results and processing generated data
• Effective at communicating technical topics to both technical and non-technical audiences
• High self-motivation and drive to execute quickly
• Collaboration skills including active listening and facilitating production discourse on problems
• Willingness to challenge the status quo in search of better, more efficient methods

Bonus points for:

• Experience with modeling/analysis software, especially ANSYS, COMSOL, and PLECS
• Experience writing Python or MATLAB data tools for processing and analyzing data
• Experience with high voltage and high current power equipment design and use – power supplies, water-cooled cables, insulation
• Experience debugging electronics hardware and test software
• Experience with designing and commissioning new test facilities
• Experience designing fluid systems – P&IDs, component selection, ASME design codes
• Experience with cryogenic equipment design for use with liquid nitrogen and supercritical helium – vacuum jacketed equipment, cryocoolers, phase separators, cold traps
• Experience with high vacuum equipment design and use – roughing pumps, turbopumps, ion gauges, residual gas analyzers
• Experience developing or improving manufacturing processes and handing off processes to production teams

Must-have requirements:

• Ability to occasionally lift up to 50 lbs
• Perform activities such as typing, climbing, standing, stooping or sitting for extended periods of time
• Willingness to occasionally travel or work required nights/weekends/on-call
• Work in a facility that contains industrial hazards including heat, cold, noise, fumes, strong magnets, lead (Pb), high voltage, high current, pressure systems, and cryogenics

#LI-Hybrid

At CFS, we excel in fast-paced environments, driven by our values of integrity, execution, impact, and self-critique. As we grow, we’re eager to bring on mission-driven folks who offer diverse perspectives and fresh ways to tackle challenges.

We value diversity deeply and are proud to be an equal opportunity employer by choice. We consider all qualified applicants equally, regardless of race, color, national origin, ancestry, citizenship status, protected veteran status, religion, physical or mental disability, marital status, sex, sexual orientation, gender identity or expression, age, or any other basis protected by law.

This role requires compliance with U.S. laws concerning the export of controlled or protected technologies or information (collectively, “Export Control Laws