Staff Quality Engineer - Advanced Metrology Integration

Cfsenergy; Harvard (MA); On-site; USD 140,000 - 200,000; Full time

Job summary

Commonwealth Fusion Systems is seeking a Staff Quality Engineer to lead dimensional management and quality strategy for HTS Magnet production and the SPARC Project. You will be the technical authority on GD&T, translating complex tolerances into manufacturable processes and verification plans.

You will design inspection architectures, mentor QC teams, implement SPC/MSA, PFMEA, and robust quality plans while coordinating with manufacturing to ensure build‑to‑print alignment and statistical rigor.

Qualifications

• BS in Mechanical, Industrial, Materials Science or Manufacturing Engineering.
• 10+ years of Quality Engineering experience in manufacturing, assembly, or equipment production.
• GD&T mastery with ASME Y14.5; translate tolerances into work instructions.
• Deep knowledge of CMM, Romer Arm, Laser tracker for complex geometries.
• ISO 9001-2015, Six Sigma, SPC, PFMEA, MSA, APQP experience.
• Knowledge of cryogenics and NDE methods; strong communication skills.

Responsibilities

• Manufacturing‑Driven GD&T interpretation with engineering to meet tolerances.
• Develop risk‑informed QA controls bridging design and shop floor.
• Architect measurement systems and inspection methods for large components.
• Lead dispositioning of NCRs with use‑as‑is or rework justifications.
• Analyze manufacturing data with control charts and capability studies.
• Create PFMEAs and Quality Plans for sub‑systems installation.
• Lead advanced MSA and Gage R&R studies for repeatable measurements.
• Provide mentorship to QC Inspectors and Quality Engineers on GD&T.

Skills

GD&T expertise (ASME Y14.5)

Metrology

Quality leadership

Statistical methods (SPC, MSA)

PFMEA

MSA

NDE knowledge

Communication skills

Process capability analysis

Mentorship

Education

BS in Mechanical, Industrial, Materials Science or Manufacturing Engineering

Tools

CMM

Romer Arm

Laser tracker

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. We’re working with policymakers and suppliers to build the energy industry of the future. Since 2018, we’ve raised nearly $3 billion in capital, making us the largest and leading private fusion company in the world.

Staff Quality Engineer – Advanced Metrology Integration

Commonwealth Fusion Systems (CFS) is seeking a Staff Quality Engineer to serve as the subject‑matter expert (SME) for dimensional management and quality strategy for our HTS Magnet production and the SPARC Project. In this high‑impact role, you will be the technical authority on Geometric Dimensioning and Tolerancing (GD&T), ensuring that novel, first‑of‑a‑kind designs are translated into manufacturable and verifiable hardware. You will collaborate with Manufacturing Engineering to develop inspection infrastructure, tooling, and process controls required to build them and will serve as the expert in applying GD&T to real‑world fabrication challenges.

Key Responsibilities

• Manufacturing‑Driven GD&T Interpretation: Take complex design requirements and work directly with Manufacturing Engineers to determine how to achieve critical tolerances using existing equipment and novel fabrication methods.
• Proactive Problem Solving: Lead the development of risk‑informed QA controls that bridge the gap between design intent and shop‑floor reality to positively impact the CFS mission.
• Inspection Architecture: Architect measurement systems and quality inspection methods specifically designed for the assembly of large metallic components, moving beyond theoretical models to executable floor‑level plans.
• Disposition Leadership: Provide high‑level leadership in dispositioning Non‑Conformance Reports (NCRs), focusing on “use‑as‑is” or “rework” justifications based on structural integrity and functional requirements.
• Process Stabilization: Regularly analyze manufacturing data using control charts and process capability studies to identify where the “build” is diverging from the “print,” escalating insights to Operations to drive immediate process adjustments.
• Sub‑system Integration: Facilitate the creation and execution of PFMEAs and Quality Plans for the installation of sub‑systems, ensuring that assembly tolerances are managed as the SPARC project scales.
• Measurement System Analysis (MSA): Lead advanced MSA and Gage R&R studies to ensure that the methods used to measure novel designs are statistically sound and repeatable in a production environment.
• Mentorship & Oversight: Provide technical coaching to QC Inspectors and Quality Engineers, specifically regarding GD&T interpretation on the shop floor.

Qualifications & Experience

• BS in Mechanical, Industrial, Material Science or Manufacturing Engineering.
• Minimum 10+ years of Quality Engineering experience in a manufacturing, assembly or equipment manufacturing environment, specifically focused on transitioning new products to production.
• GD&T Expertise: Mastery of GD&T (ASME Y14.5) with a proven ability to translate theoretical tolerances into practical manufacturing work instructions.
• Metrology: Deep knowledge of CMM, Romer Arm, and Laser tracker applied to complex geometries.
• ISO 9001‑2015, Six Sigma, Statistical Process Control (SPC), Process Capability Analysis, PFMEA, Measurement System Analysis (MSA), APQP.
• Knowledge of cryogenics.
• Minitab or JMP, MS Excel (including VBA), MS Visio.
• Excellent communication and organization skills.
• Knowledge of NDE methods including dye penetrant, ultrasonic, eddy current, and x‑ray.
• Hardware Assembly: Extensive experience with the assembly of large metallic components, welding processes and Nondestructive Testing.
• Statistical Tools: Proficiency in Minitab or JMP for conducting Process Capability Analysis and Six Sigma methodologies.
• Ability to occasionally lift up to 50 lbs.
• Willingness to travel or work required nights, weekends, or 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.

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.