Sr Electromechanical Engineer - Reel-to-Reel Web Handling

Lever, Inc.; Kearny, Northern (NJ, KY); Hybrid; USD 130,000 - 165,000; Full time

Job summary

Thea Energy is seeking a Senior Electromechanical Engineer specialized in Web Handling for Reel-to-Reel processes. You will lead architectural design of automated systems processing proprietary superconducting magnets and act as the SME for tension control and in-line inspection.

Ideal candidates have 8+ years in electromechanical design, strong NX CAD and FEA skills, and proven ability to tackle first-of-a-kind engineering challenges in a high-precision manufacturing environment.

Qualifications

• 8+ years of electromechanical design and commissioning experience with reel-to-reel equipment.
• Experience with delicate material applications (semiconductor, battery, aerospace).
• Proficiency in Beckhoff/TwinCAT 3, EtherCAT, and structured text programming.
• 3D CAD using NX and validation via FEA or multibody dynamics.

Responsibilities

• Design hardware and controls for bespoke reel-to-reel process machines with integrated software.
• Act as SME for roll-to-roll tension control, web handling, steering, and winding dynamics.
• Scope and design equipment to handle high-sensitivity materials with zero-defect tolerance.
• Manage external vendors for fabrication of large-scale equipment with safety standards.
• Design in-line inspection systems (vision, laser) to capture process data.
• Develop strategies to improve throughput and yield in continuous manufacturing.

Skills

Beckhoff TwinCAT 3

EtherCAT

Structured text programming

Taper Tension

Winding algorithms

NX CAD

Finite Element Analysis (FEA)

Multibody dynamics

Education

BS in Mechatronics

MS in Mechanical or Electrical Engineering

PhD in a related field

Tools

NX

FEA software

Job description

Thea Energy is seeking a Senior Electromechanical Engineer specialized in Web Handling for Reel-to-Reel processes. You will lead architectural design of automated systems processing proprietary superconducting magnets and act as the SME for tension control and in-line inspection.

Ideal candidates have 8+ years in electromechanical design, strong NX CAD and FEA skills, and proven ability to tackle first-of-a-kind engineering challenges in a high-precision manufacturing environment.