Staff Dimensional Engineer – SPARC

Commonwealth Fusion; Harvard (MA); On-site; USD 130,000 - 200,000; Full time

Benefits offered by this job

Equity

13 company‑wide holidays

Flexible vacation days

Health, dental, and vision insurance

401(k) with employer matching

Professional growth opportunities

Job summary

Commonwealth Fusion Systems seeks a Staff Dimensional Engineer to lead dimensional management across SPARC magnet production and future ARC plants. You will define GD&T, tolerance strategies, and acceptance criteria to ensure buildable, verifiable hardware.

You will supervise a metrology team and collaborate with Quality Engineering to control variation through assemblies, supporting design changes and supplier requirements.

Qualifications

• BS in Mechanical, Industrial, Materials Science, Manufacturing, or Aerospace Engineering.
• 10+ years in dimensional engineering on complex hardware.
• Mastery of GD&T (ASME Y14.5) as author and reviewer; GDTP certified preferred.
• Proven tolerance stack‑up capability (1D RSS and 3D variation).
• Experience applying dimensional management to large assemblies and development of inspection criteria.
• Ability to translate design intent into verifiable inspection requirements and acceptance criteria.
• Excellent communication and organizational skills.

Responsibilities

• Set GD&T and datum strategy aligning with design intent and manufacturability.
• Perform 3D variation analysis and stack‑up on large assemblies.
• Architect inspection requirements for large components and assemblies.
• Drive identification and flow‑down of key characteristics to drawings and supplier requirements.
• Support disposition of Non-Conformance with dimensional impact analysis.
• Review engineering changes for dimensional impact during SPARC assembly.
• Coach QC Inspectors and design engineers on GD&T interpretation.

Skills

GD&T mastery

Tolerance analysis

Dimensional management

Metrology knowledge

Inspection requirements

Education

BS in Mechanical/Industrial/Materials/Aerospace

Tools

3DCS

VisVA

MS Excel

Job description

About Commonwealth Fusion Systems:

Commonwealth Fusion Systems is on a mission to deliver the urgent transition to fusion energy.

Combining decades of research, top talent, and new technologies, we’re designing and building commercially viable fusion power plants. And we're working with policymakers, suppliers, and many others to build the energy industry of the future.

We’re in the best position to make it happen. Since 2018, we’ve raised $4 billion of capital, making us the largest and leading fusion company in the world.

Now we’re looking for more thinkers, doers, builders, and makers to join us. People who’ll bring new perspectives, solve tough problems, and thrive as part of a team.

If that’s you and this role fits, we want to hear from you.

Join the power movement as a Staff Dimensional Engineer – SPARC

SPARC is a first-of-a-kind machine, and it presents some of the hardest dimensional management problems in industry today: large high-field magnets, tight tolerances on complex geometries at meter scale, novel materials, and assembly stack-ups with no precedent to copy from. CFS is seeking a Staff Dimensional Engineer to be the technical authority for dimensional management across HTS Magnet production and the SPARC project.

This is a role for someone who wants to define a discipline, not inherit one. You will own how design intent becomes buildable, verifiable hardware: setting GD&T and datum strategy with Engineering, analyzing variation propagation through assembly sequences before hardware proves it the hard way, and defining what we measure and to what acceptance criteria. Your decisions will shape how fusion hardware is toleranced, measured, and accepted, on SPARC and on the ARC power plants that follow.

You will work alongside a metrology team equipped with laser trackers, portable CMM arms, and structured-light scanning, and with an established Quality Engineering organization that owns statistical process control and measurement system analysis, so your focus stays on the geometry.

What you’ll do:

• Set GD&T and datum strategy in partnership with Engineering, translating design intent into tolerancing that is functionally sound and manufacturable with our equipment and fabrication methods
• Perform tolerance stack-up and 3D variation analysis on large complex assemblies, predicting variation propagation through build sequences and informing tooling, indexing, and assembly strategy
• Architect inspection requirements for large metallic components and assemblies, defining what to measure, how, and to what acceptance criteria
• Drive key characteristic identification and flowdown from top-level assembly requirements to component drawings and supplier requirements
• Support disposition of Non‑Conformance Reports with dimensional analysis, quantifying the assembly‑level impact of as‑built deviations to inform use‑as‑is, rework, repair, or scrap decisions
• Review engineering change packages for dimensional impact as designs mature through SPARC assembly and integration
• Coach QC Inspectors, Quality Engineers, and Design Engineers on GD&T interpretation and dimensional management practice

What we’re looking for:

• BS in Mechanical, Industrial, Materials Science, Manufacturing, or Aerospace Engineering
• 10+ years of dimensional engineering experience on complex hardware (airframes, vehicle structures, turbomachinery, large equipment, or comparable)
• Mastery of GD&T (ASME Y14.5) as an author, not only an interpreter: datum strategy, tolerance allocation, and drawing review authority; GDTP certification strongly preferred
• Proven tolerance stack‑up capability, both 1D (RSS, worst‑case) and 3D variation analysis (3DCS, VisVA, or equivalent
• Experience applying dimensional management to large assemblies: indexing strategies, key characteristics, and assembly sequence variation
• Demonstrated ability to translate design intent into inspection requirements and acceptance criteria
• Excellent communication and organization skills

Bonus points for:

• Experience standing up dimensional management practices in a new program or organization (NPI, clean‑sheet aircraft or vehicle programs)
• Working knowledge of SPC, process capability analysis, MSA/Gage R&R, and PFMEA
• Familiarity with metrology instruments applied to complex geometries (laser tracker, portable arms, CMM, structured light)
• Knowledge of NDE methods (PT, UT, ET, RT)
• Knowledge of cryogenics
• Minitab or JMP; MS Excel (including VBA); MS Visio

Must‑have Requirements:

• Ability to occasionally lift up to 50 lbs
• Willingness to travel or work required nights/weekends/on‑call occasionally
• Perform activities such as stooping, climbing, typing, standing, or sitting for extended periods of time
• 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

$130,000 - $200,000 a year

Salary range for this full‑time position + equity + benefits. The actual salary will depend on level, location, qualifications, and experience. The range displayed on each job posting reflects new hire salaries for the position across all US locations.

Benefits include:

• Competitive compensation with equity
• 13 Company‑wide Holidays
• Flexible vacation days
• 10 sick days
• Generous parental leave policy
• Health, dental, and vision insurance
• 401(k) with employer matching
• Professional growth opportunities
• Team‑building activities

#LI-Onsite

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”). Any offer of employment will be contingent on the need for compliance with such Export Control Laws.