Software Control Engineer

ZAP Surgical Systems, Inc.; San Carlos (CA); On-site; USD 120,000 - 160,000; Full time

Job summary

A medical technology firm is seeking a Senior or Staff level Controls Software Engineer to develop core components for a safety-critical system application. This role involves designing control systems using Beckhoff PLCs and real-time programming in TwinCAT 3. The ideal candidate will have 5+ years of experience in regulated domains, strong skills in PLC programming, and the ability to work collaboratively with cross-functional teams. This position is critical for delivering life-saving treatments in a fast-paced, high-stakes environment.

Qualifications

• 5+ years in control software development, including 3+ years in real-time or safety-critical systems.
• Proven track record in regulated domains like medical, automotive, or aerospace.
• Experience with hardware and networking interfaces (e.g., ADS, EtherCAT, TCP/IP).

Responsibilities

• Design and build a control system using Beckhoff PLCs and TwinCAT3.
• Collaborate with clinical engineers to understand user needs.
• Document software architecture and protocols to meet medical device standards.

Skills

PLC programming using TwinCAT 3 Structured Text

Motion control systems using Beckhoff PLCs

C# application development

Strong interpersonal and communication skills

Education

Bachelor’s or Master’s degree in Computer Science, Physics, Mathematics, or Engineering

Tools

TwinCAT 3

Beckhoff PLCs

C#

Job description

About the Role

We are seeking a Senior or Staff level Controls Software Engineer to work on the next-generation Dynamic Treatment Delivery application for the ZAP-X radiosurgery system. This position is a hands-on technical role for an individual who excels in high-stakes environments. You will implement core components of a safety-critical system applications in Beckhoff TwinCAT 3 Structured Text for real-time control, deterministic performance, and fault tolerance. You will also collaborate with clinical, service, and hardware engineers to understand and document requirements. Your experience in regulated domains such as medical devices, automotive, or aerospace will help us deliver precise, reliable, and life-saving treatments to patients with brain tumors, metastatic cancers, and functional diseases.

Key Responsibilities

• Design and build a control system consisting of real-time, safety-critical and motion control subsystems using Beckhoff PLCs and TwinCAT3 software.
• Implement Modules and HMIs using Beckhoff TwinCAT 3 Structured Text and HMI framework for real-time motion control.
• Enable data exchange and control of TwinCAT Systems from Software (C#) using ADS protocol.
• Collaborate with clinical and service engineers to understand user needs and investigate discrepancies in system behavior.
• Apply agile methodologies to manage development cycles, bug fixes, and feature rollouts. Collaboratively break-down work items into manageable pieces.
• Optimize system performance for low-latency, high-reliability execution across multiple threads and processes.
• Document software architecture, communication protocols, and safety logic to meet medical device regulatory standards.

Required Qualifications

Education

• Bachelor’s or Master’s degree in Computer Science, Physics, Mathematics, or Engineering.

Experience

• At least 5 years in control software development, including at least 3 years in real-time or safety-critical systems.
• Proven track record of developing complex applications in regulated domains (e.g., medical, automotive, aerospace).
• Strong proficiency in PLC programming using TwinCAT 3 Structured Text.
• Experience building motion control systems using Beckhoff PLCs and Controllers.
• Experience working with various hardware and networking interfaces (e.g., ADS, EtherCAT, Serial Comm, RS485, Modbus, TCP/IP)
• Experience writing applications in C#, .Net to interface with Beckhoff PLC over ADS.
• Familiarity with deterministic programming and fault-tolerant system design.

Other Skills

• Strong interpersonal and communication skills for cross-functional collaboration.
• Operates effectively in a regulated environment with design control and testing.
• Knowledge of safety standards (e.g., IEC 61508, ISO 14971) and risk management practices.
• Experience developing software that controls radiotherapy/diagnostic medical devices.