Senior Test Engineer

U.S. Fusion Energy; Energy (IL); On-site; USD 182,000 - 214,000; Full time

Benefits offered by this job

Medical, dental, vision plans

PTO: 31 days

401(k) match up to 5%

Parental leave

Disability and life insurance

Job summary

Helion is seeking a Test Engineer to design, build, and sustain electrical test systems supporting PCBA and high-voltage assemblies for fusion generators. You will operate at the intersection of design engineering and production, ensuring robust, safe test infrastructure for technicians in a hands-on lab environment on-site in Everett, WA.

You will develop test fixtures, automate sequencing with Python/PLC, and collaborate with design and production teams to improve first-pass yield and hardware

Qualifications

• Bachelor’s degree in electrical engineering, Mechatronics, or a related field.
• 5+ years of experience developing and supporting electrical or electronic test systems in R&D or production environments.
• Experience designing PCBAs for test fixtures or test systems, including schematic capture, layout, and bring-up.
• Proficiency with ECAD tools such as Altium Designer or equivalent.
• Hands-on experience designing, building, wiring, and debugging test racks and fixtures.
• Experience with Python or PLC-based systems for test sequencing, automation, and data acquisition.
• Proficiency with lab instrumentation (oscilloscopes, DMMs, power supplies, etc.).
• Strong safety and FPY/yield/data interpretation capabilities.
• Strong cross-functional collaboration and clear communication.

Responsibilities

• Design and deliver electrical test systems for PCBA and high-voltage assemblies, including rack architecture and instrumentation.
• Design fixture PCBA layouts, schematic capture, and bring-up for validation and diagnostics.
• Build, wire, debug, and maintain test racks, fixtures, distribution, and data acquisition.
• Develop data acquisition and control tools using Python or PLC-based systems for sequencing and reporting.
• Write and maintain test procedures, calibration standards, and test limits with engineering and production leads.
• Analyze test data to generate FPY, yield, and performance metrics and work with design teams to improve robustness.
• Collaborate hands-on with technicians to ensure safe, repeatable test execution and scalable systems.
• Support deployment of test infrastructure at contract manufacturers.

Skills

Electrical test systems

PCBAs for test fixtures

ECAD: Altium Designer

Lab instrumentation

Python/PLC automation

DFMEA/safety

Cross-functional collaboration

Education

Bachelor's degree in electrical engineering or related

Mechatronics background

Tools

Altium Designer

Job description

About Helion

We are a fusion power company based in Everett, WA, with the mission to build the world's first fusion power plant, enabling a future with unlimited clean electricity. Our vision is a world with clean, reliable, and affordable energy for everyone.

Location

Everett, WA

Employment Type

Full time

Location Type

On-site

Department

Production

Compensation

• $182K – $214K

Compensation Range: $182K - $214K

Company Overview

Since Helion's founding in 2013, we have raised $1.5 billion from long-time investors such as Sam Altman, Mithril, and Capricorn Investment Group as well as new investors including Thrive Capital, LightSpeed Venture Capital, SoftBank, and others to propel us forward. Our current prototype, Polaris, has reached record-breaking plasma temperatures of 150 million degrees Celsius (13 keV). Helion is continuing to iterate and on the path to the world's first fusion power plant, Orion.

What You Will Be Doing

As a Test Engineer at Helion, you will be responsible for designing, building, and sustaining the electrical test systems that validate PCBAs, power electronics, and high-voltage assemblies used across our fusion generators. You will operate at the intersection of design engineering and production, ensuring that test infrastructure is robust, repeatable, and safe for hand‑on execution by technicians. Your work will directly enable faster hardware iteration, improved first‑pass yield, and reliable delivery of mission‑critical electrical systems that support Helion's fusion generators and pulsed-power architecture. This is a hands‑on, lab‑based role reporting to the Production Manager and working closely with Design Engineers, R&D Engineers, and Technicians/Supervisors. This is onsite role located at our Everett, WA office.

You Will

• Design and deliver electrical test systems for PCBA and high‑voltage assemblies, including test rack architecture, fixture design, instrumentation selection, electrical integration, and supporting automation
• Design test fixture PCBAs used within test racks and fixturing, owning schematic capture, layout, review, and bring‑up to enable functional validation and diagnostics of production hardware
• Build, wire, debug, and maintain complete test racks and fixtures, including power distribution, safety interlocks, signal routing, and data acquisition integration
• Develop and maintain data acquisition and control tools using Python or PLC‑based systems to support sequencing, measurement, and reporting
• Write and maintain test procedures, calibration standards, and test limits in collaboration with design engineering and production leadership
• Analyze test data to generate FPY, yield, and performance metrics, and partner with design teams to refine thresholds and improve robustness
• Work hands‑on with technicians and supervisors to standardize safe, repeatable test execution and continuously improve test system scalability and maintainability
• Support deployment and sustainment of test infrastructure at Contract Manufacturers, including validation of test hardware and associated electronics

Required Skills

• Bachelor’s degree in electrical engineering, Mechatronics, or a related field
• 5+ years of experience developing and supporting electrical or electronic test systems in R&D or production environments
• Demonstrated experience designing PCBAs for test fixtures or test systems, including schematic capture, layout, review, and bring‑up
• Proficiency with ECAD tools such as Altium Designer or equivalent
• Strong hands‑on experience designing, building, wiring, and debugging test racks, fixtures, harnesses, and control systems
• Working experience with Python or PLC‑based systems for test sequencing, automation, and data acquisition
• Proficiency using standard lab instrumentation including oscilloscopes, DMMs, power supplies, electronic loads, and spectrum analyzers
• Strong understanding of electrical safety principles and lab best practices
• Strong analytical skills with experience interpreting FPY, yield, or performance metrics
• Proven ability to collaborate across design engineering, production, and technician teams and communicate clearly at multiple levels

Benefits

Our total compensation package includes benefits, including but not limited to:

• Medical, Dental, and Vision plans for employees and their families
• 31 Days of PTO (21 vacation days and 10 sick days)
• 10 Paid holidays, plus company‑wide winter break
• Up to 5% employer 401(k) match
• Short term disability, long term disability, and life insurance
• Paid parental leave and support (up to 16 weeks)
• Annual wellness stipend

Equal Opportunity Employer

Helion is an equal opportunity employer and value diversity at our company. We do not discriminate based on race, religion, color, national origin, gender, sexual orientation, age, marital status, veteran status, or disability status. If you need assistance or an accommodation during the interview process, please let us know.